Vacuum Electric Switch Co. - VESCO

9/10/2020 2:39 PM

Rev . 7

1 © The Vacuum Electric Switch Co. 2020

Vacuum Electric Switch Co.

Switches for Special Applications

15kV 600A Three Pole, Pg. 4 34 or 46kV 600A Single Pole, Pg. 5 & 6 34kV 300A Three Pole, Pg. 7

46kV 300A Single Pole, Pg. 9 69kV 300A Single Pole, Pg. 9 69kV 600A Single Pole, Pg. 10

15kV 600A Two Pole, Pg.11 15kV 600A Single Pole, Pg.11 34kV 600A Sectionalizer, Pg. 12

34kV 600A Resistor Shorting Switch, Pg. 12 15/34kV 1000/600A Laboratory Switch, Pg.13 34kV 600A Harmonic Filter Switch, Pg.13

9/10/2020 2:39 PM Rev. . 7


Vacuum Electric Switch Company™ products can be hazardous.

Vacuum Electric Switch Co.™ products are high voltage equipment with the potential to kill or injure individuals not following appropriate pro-cedures. Personnel must be trained according to an established standard such as NFPA 70E, Standard for Electrical Safety in the Workplace, available from www.nfpa.org or: National Fire Prevention Association 1 Battery March Park, P.O. Box 9101 Quincy, MA 02269-9101 USA This standard establishes appropriate safety training and procedures for ser-vicing this equipment. Vacuum Electric Switch products are not personal safety devices. They should never be used to isolate high voltages from equipment being serviced by personnel because they do not provide isolation with a visible break. All equipment must be de-energized, locked out, grounded, and proven de-energized prior to performing maintenance. Switches have two sources of energy: one is from the high voltage source, and the other is from the control through the control cable. Switches contain stored energy in springs. Completely de-energizing a switch requires removing both sources of energy and immobilizing the springs in the switch mechanism. Controls have both a source of energy as well as stored energy in capaci-tors. Controls require locking out their electric power source, and removing the stored energy in their capacitors prior to servicing. Hi-pot testing is part of switch maintenance that uses dangerous high voltages. Safe hi-pot testing requires a cleared area between the equipment under test and personnel as specified by NPFA 70E.

9/10/2020 2:39 PM

Rev . 7


*The Vacuum Electric Switch Co. manufactures vacuum switches which are suitably interchangeable with Joslyn Hi-Voltage’s vacuum switches of the same rating. The Joslyn designations VBM*, VBT*, and VBU* are abbreviations for the descriptive phrases vacuum breaker miniature, vacuum breaker transformer, and vacuum breaker up-right respectively. The Vacuum Electric Switch Co.’s switches and parts are of its own design and methods of manufacture, which may not be the same as employed by Joslyn. Where product performance is reported, it is from testing of Vacuum Electric Switch Co.’s products and is not necessarily indicative of the performance of comparable products wholly manufactured by Joslyn. The Vacuum Electric Switch Co. is not endorsed or associated with the Joslyn Hi-Voltage a subsidiary of ABB.

* VBM, VBU, and VBT are Joslyn trademarks which are owned by ABB.

Safety ………………………………………………………. Page 2 Specifications & Accessories for New Switches Switch Types*……….……………….……………….. Page 4 Switch Ratings Table…………………………………. Page 14 Switch Accessories…………..………………………. Page 15 Service Equipment……………………………………. Page 16 Switch Controls…….…………….………………….. Page 19 Power Requirements for Solenoid Operated Switches. Page 26 Maintenance Inspection, Testing, and Adjustment Instructions ……. Page 27 Fastener Torque Requirements ……………………….. Page 32 Sample Data Recording Sheets ……………………… Page 33 Switch Wiring Schematics…………………………… Page 35 Cable Color Codes………………………………… Page 39 Switch Replacement Parts……………………………. Page 40 Housings & Solenoids…...……………………………. Page 45 Motor Mechanism Assembly…………...……………… Page 53 Joslyn Control Circuit Boards………………………… Page 57 Replacement Parts List………………………………... Page 58 Reference Materials Failure Diagnostic Charts……………………………… Page 67 Recommended Maintenance Schedule…………………. Page 72 Analyzing Vacuum Interrupter Module Failures……….. Page 76 Failures Not Visible…………………………………….. Page 76 Overheating Evidence………………………………… Page 77 Explosive Force……………………………………… Page 78 Switch Mechanical Failures……………………………. Page 80 Cotter Pin Failure………………………………………. Page 80 Module Failure………………………………………….. Page 80 Solenoid Operated Switches…………………………….. Page 83 Catastrophic Switch Failure…………………………….. Page 84 Motor Operated Switches………………………………. Page 92 Loss of VBM and VBT Adjustments…………………… Page 95 VBU Switches………………………………………… . Page 100 Modules……………………………………………….. . Page 100

Vacuum Electric Switch Company 24 Hour Line

(330) 374-5156 Fax: (330) 374-5159 E-mail: [email protected]

President: Cecil Wristen

Vice President: Sandra Wristen Manufacturing & Service Manager: Dale Mozina

Engineering Manager: Frank Ricard

9/10/2020 2:39 PM Rev. . 7


SWITCH CONFIG.

BIL kV (T:T-T:G)

VOLTAGE RATING

kV

CURRENT RATING A

OPERATING MECHANISM

TYPE

CONTROL VOLTAGE

OUTLINE DRAWING

VES SWITCH

PART NO.

3 POLE 110-150 15 600 SOLENOID 120VAC 1001057 1001055G1

3 POLE 110-150 15 600 15 PIN MOTOR 48VDC/120VAC 1001057 1002520G1

3 POLE 110-150 15 600 15 PIN MOTOR 125VDC 1001057 1002520G2

3 POLE 110-150 15 600 35 PIN MOTOR 48VDC/120VAC 1001057 1003308G1

3 POLE 110-150 15 600 35 PIN MOTOR 125VDC 1001057 1003308G2

The common uses of this switch are sectionalizing and arc furnace or capacitor bank switching. This switch may have either a motor or solenoid operated mechanism. These two mechanisms differ in the com-plexity of the required control systems, control current demand, available operating voltages, mechanical life, and the precision of the timing of switch contact closing.

Motor operated switches are used for capacitor bank switching and sectionalizing but not arc furnace switching. They can have simple control systems since control current demand is less than six amperes. The motor mechanism cannot be used where simultaneous contact closure in more than one switch is required. The motor mechanism has a limited life of about 30,000 operations which is much less than the more than 200,000 operations achievable by a solenoid mechanism. Motor operated switches with 15 or 35 pin con-nectors have two each form A (e.g., normal open) and B (e.g., normal closed) or six each form A and B con-tacts respectively. A common error which may damage the motor operator is to connect it to the wrong con-trol voltage. A switch’s control voltage can be determined by examining its relay panel. Relay panels are shown starting on page 36. Repair parts for this switch are found beginning on page 41 and for the motor mechanism, beginning on page 53.

Common uses of the solenoid operated switch are both capacitor and also arc furnace switching. Un-commonly, two or more of these switches may be used along with three resistor modules to form a resistor insertion switch. The solenoid operated switch can be operated with three modules connected in parallel. Each module’s current rating is de-rated to 500A when connected in parallel for a total current of 1500A. Three separate switches are then required to make a three phase set. Solenoid operated switches have one form A (e.g., normal open) and one form B (e.g., normal closed) contact.

The solenoid operated switch requires a more elaborate control because each solenoid requires a current in the range of 60 to 65 amperes peak for 1½ cycles. If the solenoid takes longer than 1½ cycles to operate, the available power is inadequate for reliable long term operation. The solenoid coils may fail, and the mod-ules may not close completely causing them to burn up. The requirement for a large current source can be overcome by using a stored energy control shown on page 19. For an existing installation the VES Boost Box on page 20 can be used to correct an inadequate current supply. The controls for arc furnace switching are shown starting on page 23. The resistor module for building a resistor insertion switch is shown on page 15.

Alternate Terminal Pad Arrangements

A B C

9/10/2020 2:39 PM

Rev . 7


SWITCH CONFIG.

BIL KV (T:T-T:G)

VOLT-AGE

RATING kV

CURRENT RATING A

OPERATING MECHANISM

TYPE

CONTROL VOLTAGE

OUTLINE DRAWING

VES SWITCH

PART NO.


1 POLE 200-200 34 with grading

caps. 600 SOLENOID 120VAC 1001565 1004355G1

This switch is used for both capacitor and arc furnace switching. It is solenoid operated because it is used in three phase sets requiring simultaneous contact closure. It can close at zero voltage for capacitor switching or at peak voltage for arc furnace switching. Its solenoid operating current is 60 to 65 amperes peak for 1½ cycles. If the solenoid operating time exceeds 1½ cycles, switch operation will not be reliable. An inadequate current supply is a common cause of improper operation.

When this switch is used for capacitor switching and does not have 32 inches of free space surrounding it, the switch requires grading capacitors to assure proper operation. The grading capacitors assure that the re-covery voltage is equally distributed over its two vacuum interrupters in series.

For capacitor switching, this switch can be operated from a variety of AC and DC sources and is best op-erated by selecting from the controls shown on page 21. This switch has one form A (e.g., normal open) and one form B (e.g., normal closed) auxiliary contact. Repair parts are shown beginning on page 41.

Multiple switches are used in parallel for arc furnaces with up to 4000 amperes primary current. The switch current rating is de-rated to 500A when used in parallel. Arc furnace controls that can operate from one to six switches per phase are shown on page 24. An arc furnace transformer control can optionally be operated using either resistor insertion or peak voltage closing to reduce in-rush currents.

Accessories available for this switch include both current limiting reactors and resistor modules. The 30 microhenry reactor replaces the buss bar between the two modules. The reactor is used to limit in-rush cur-rents when two capacitor banks are installed in parallel on a single buss. This switch also can be adapted as a resistor insertion switch by installing two 80 ohm resistor modules, one each, on top of the two vacuum inter-rupter modules. The two resistor modules are then series connected with the buss bar and have a total series resistance of 180 ohms. The controls required are shown starting on page 21. The reactors and resistors are shown on page 15.

9/10/2020 2:39 PM Rev. . 7


SWITCH CONFIG.

BIL kV (T:T-L-G)

VOLTAGE RATING

kV

CURRENT RATING A

OPERATING MECHANISM

TYPE

CONTROL VOLTAGE

OUTLINE DRAWING

VES SWITCH

PART NO.



capacitors 600 SOLENOID 120VAC 1002862 1002861G3

This switch is principally used for arc furnace switching but also has limited use for capacitor switching. When the switch is used for capacitor switching and is not surrounded by 32 inches of free space, it must have grading capacitors to assure that the recovery voltage is equally distributed over the two vacuum interrupters in series. Otherwise the switch’s performance will be degraded.

The switch is solenoid operated because it is used in three phase sets requiring simultaneous contact clo-sure. Capacitor switching is limited to switching solidly grounded 46kV systems having RMS currents of 200 amperes maximum. The switch can be used to switch an arc furnace at 46kV. Its current capacity can be in-creased by connecting switches in parallel. Switches connected in parallel are de-rated to 500A. This switch has one form A (e.g., normal open) and one form B (e.g., normal closed) auxiliary contact. Capacitor switching is best done with a stored energy control shown on page 19. An arc furnace control is shown on page 23. This switch’s repair parts are shown beginning on page 41.

9/10/2020 2:39 PM

Rev . 7


Switches with 0.160 Inch Gap with Grading Capacitors with No Known Joslyn™ Equivalent

SWITCH CONFIG.

BIL kV (T:T-T:G)

VOLT-AGE

RATING kV

CURRENT RATING A

OPERATING MECHANISM

TYPE

CONTROL VOLTAGE

OUTLINE DRAWING

VES SWITCH

PART NO.

3 POLE 200:200 34 300 15 PIN MOTOR 24VDC 1003256 1003315G5

3 POLE 200:200 34 300 15 PIN MOTOR 48VDC/120VAC 1003256 1002521G5


3 POLE 200:200 34 300 15 PIN MOTOR 220VAC 1003256 1003315G2





3 POLE 200:200 34 300 SOLENOID 120VAC 1003256 1002201G2

Switches with 0.160 Inch Gap (Comparable to Joslyn™ Switches with Similar Ratings)

SWITCH CONFIG.

BIL kV (T:T-T:G)

VOLT-AGE

RATING kV

CURRENT RATING A

OPERATING MECHANISM

TYPE

CONTROL VOLTAGE

OUTLINE DRAWING

VES SWITCH

PART NO.









3 POLE 200:200 34 300 SOLENOID 120VAC 1003256 1002201G1

9/10/2020 2:39 PM Rev. . 7


The Vacuum Electric Switch Co. is offering this switch in three different versions to improve restrike resistance during capacitor switching. The improvements in restrike resistance are achieved by first adding grading capacitors and second by increasing the open gap between the vacuum contacts from 0.160 to 0.320 inches.

The geometric configuration of this switch may cause the recovery voltage distribution over the two vacuum interrupter in series to be unequal. This is most likely to occur when the switch is used on poles where objects closer than 32 inches in proximity may cause a larger portion of the recovery voltage to ap-pear across the upper module. The switches capacitor switching capability will be reduced. Grading capac-itors tend to equalize the capacitance across each vacuum interrupter diminishing the effect of parasitic ca-pacitance. The recovery voltage withstand capability is further improved by increasing the contact open gap from 0.160 to 0.320 inches. The larger gap requires more energy than is available from a solenoid mecha-nism, so it is only possible with motor operated switches.

The common uses of this 34kV switch are either capacitor switching or sectionalizing. It can have either a solenoid or motor operated mechanism. The principal differences between the two mechanisms are the complexity of the control, control current demand, available operating voltages, and mechanical life. A mo-tor operated switch requires a simple control system because the control operating current is less than 6 am-peres. Motor operated switches are available with a variety of control voltages. The VES motor operator has a limited life of approximately 30,000 operations as compared to the 200,000 operations for the solenoid operator.

Motor operated switches with 15 or 35 pin connectors have two each form A (e.g., normal open) and B (e.g., normal closed) or six each form A and B contacts respectively. A common error which may damage a motor operated switch is to connect it to the wrong control voltage. The appropriate voltage for a motor operator switch can be determined by examining the relay panel installed on the motor operator. Relay pan-els are shown on pages 36-38. Motor operator repair parts are found starting on page 51.

The solenoid operated version of this switch is particularly susceptible to having its control current be-ing inadequate because its has twice as many solenoids as the other switches. Demonstrating inadequate current requires a digital oscilloscope with a current probe. Reliable operation requires either a substantial current source or a stored energy control. Existing installations with too small a current supply can be cor-rected by installing the VES Boost Box shown on page 20. An adequate current on new installations can be assured by installing the stored energy control such as shown on page 19.

Switch repair parts are shown starting on page 41. Replacement modules for this 34kV 300A switch are available both with and without grading capacitors. Modules with and without grading capacitors can not be installed on the same switch.

Switches with 0.320 Inch Gap with Grading Capacitors with No Known Joslyn™ Equivalent

SWITCH CONFIG.

BIL kV (T:T-T:G)

VOLT-AGE

RATING kV

CURRENT RATING A

OPERATING MECHANISM

TYPE

CONTROL VOLTAGE

OUTLINE DRAWING

VES SWITCH

PART NO.









9/10/2020 2:39 PM

Rev . 7


SWITCH CONFIG.

BIL kV (T:T-T:G)

VOLTAGE RATING

kV

CURRENT RATING A

OPERATING MECHANISM

TYPE

CONTROL VOLTAGE

OUTLINE DRAW-

ING

VES SWITCH

PART NO.




SWITCH CONFIG.

BIL KV (T:T-T:G)

VOLTAGE RATING

kV

CURRENT RATING A

OPERATING MECHANISM

TYPE

CONTROL VOLTAGE

OUTLINE DRAW-

ING

VES SWITCH

PART NO.




The 46 and 69kV switches shown above are commonly used for capacitor bank switching in substations. They may also be used for switching induction furnaces. When the switch is used for capacitor switching and is not surrounded by 32 inches of free space, the switch must have grading capacitors to assure that the recov-ery voltage is equally distributed over the three or four vacuum interrupters in series. Otherwise the switch’s performance will be degraded.

These switches are solenoid operated because they are used in three phase sets requiring simultaneous contact closure. The switches can precisely close at zero voltage to reduce capacitor bank in-rush currents. The solenoid operating current is 60 to 65 amperes peak for 1½ cycles per switch mechanism. If the switch solenoid takes longer than 1½ cycles to operate, switch operation will be unreliable. Failed modules or sole-noid coils may be a result. This switch is best operated with a stored energy control as shown on page 19. These switches have one form A (e.g., normal open) and one form B (e.g., normal closed) auxiliary contact. Repair parts are shown beginning on page 41.

9/10/2020 2:39 PM Rev. . 7


This switch is used for both arc furnace and capacitor switching and is generally known as the Joslyn™ VBU* because there is no other widely known generic name for this switch. The 2000A and 3000A modules are original products of the Vacuum Electric Switch Co. and are used for very large arc furnaces at 34kV. At 69kV and above, this switch may be the only switch available with a practical operating life for switching arc furnaces. The Vacuum Electric Switch Co. manufactures new VBU modules and switch operating mechanisms as shown on page 40. The Vacuum Electric Switch Co. builds a special control for switching VBU switches for both capacitor and arc furnace switching applications. This switch can be closed at peak voltage or used as a resistor insertion switch to reduce in-rush current transients. Controls are available that can switch as many six VBU poles in parallel or a total of eighteen switches. Controls are shown on page 25.

* VBU is Joslyn trademark and owned by ABB..

MODULES BIL kV

(T:T-T:G)

VOLTAGE RATING

kV

CURRENT RATING A

OPERATING MECHANISM

TYPE

CONTROL VOLTAGE

PART NO.

2 200 34 2000 SOLENOID 120VAC 1003543G1

2 200 34 3000 SOLENOID 120VAC 1003543G2

4 350 72 600 SOLENOID 120VAC 1001513G1

7 550 121 600 SOLENOID 120VAC 1001513G3

8 750 145 600 SOLENOID 120VDC 1001513G6

Vacuum Breaker Up-right Switch

34kV 3000A Switch

69kV 600A Switch

9/10/2020 2:39 PM

Rev . 7


SWITCH CONFIG.

BIL kV (T:T-T:G)

VOLTAGE RATING kV

CURRENT RATING A

OPERATING MECHANISM

TYPE

CONTROL VOLTAGE

OUTLINE DRAWING

VES SWITCH

PART NO.

1 POLE 150 15 600 SOLENOID 120VAC 1000641 1000579G1

SWITCH CONFIG.

BIL kV (T:T-T:G)

VOLTAGE RATING kV

CURRENT RATING A

OPERATING MECHANISM

TYPE

CONTROL VOLTAGE

OUTLINE DRAW-

ING

VES SWITCH

PART NO.

1 POLE T

150 15 600 SOLENOID 120VAC 1003374 1001178G3

1 POLE L

150 15 600 SOLENOID 120VAC 1001182 1001178G1

This single pole switch is used for synchronous closing of capacitor banks to reduce in-rush currents. It is available with two terminal pad orientations. With the terminal pads perpendicular to the length of the switch, it is used with the two pole switch above to switch capacitor banks at zero voltage. The longitudinal form above is used in three phase sets to switch capacitor banks at zero voltage. These switches contain one form A (e.g., normal open) and one form B (e.g., normal closed) auxiliary contact. The required controls are shown starting on page 21. The repair parts are the same as for the three pole 15kV switch and are found beginning on page 41.

Transverse Longitudinal

This solenoid operated two pole switch has two applications. The first is to achieve 1000 amperes of current capacity at 15kV by connecting the two modules in parallel with buss bars. In this configuration it is used for arc furnace switching. When the modules are connected in parallel, three separate switch mechanisms are re-quired to make a three phase set. This switch’s controls for arc furnace switching are shown starting on page 24. The second application is in conjunction with the transverse single pole switch shown below for switching ca-pacitor banks at zero voltage. The control required for this application is found on page 21. Repair parts are the same as for a 15kV three pole switch and are found starting on page 41.

9/10/2020 2:39 PM Rev. . 7


SWITCH CONFIG.

BIL kV (T:T-T:G)

VOLT-AGE

RATING kV

CURRENT RATING A

OPERATING MECHANISM

TYPE

CONTROL VOLTAGE

OUTLINE DRAWING

VES SWITCH

PART NO.





SWITCH CONFIG.

BIL kV (T:T-T:G)

VOLTAGE RATING kV

CURRENT RATING A

OPERATING MECHANISM

TYPE

CONTROL VOLTAGE

OUTLINE DRAW-

ING

VES SWITCH

PART NO.

1 POLE 200 -350 34 600 SOLENOID 120VAC 1002864 1002863G1

This switch is used for sectionalizing 34kV solidly grounded systems only. The switch is motor operated because it is used as a sectionalizing switch in remote locations where a limited current supply is available and a simple control is an advantage. The control current is only 6 amperes. Switches with 15 or 35 pin connect-ors have two each form A (e.g., normal open) and form B (e.g., normal closed) or six each form A and form B contacts respectively.

This switch is a 34kV switch with 350kV BIL line-to-ground insulators commonly used on 69kV sys-tems. The extra creepage is useful where atmospheric contamination is a problem. This switch is also used to short insertion resistors on an arc furnace having a 69kV primary voltage. This switch is solenoid operated because to prevent over heating, the resistors must be shorted at 100 milliseconds after being energized. On-ly the solenoid operated switch has the precision to meet this timing requirement. This switch contains one form A (e.g., normal open) and one form B (e.g., normal closed) auxiliary contact. A control for operating this switch is shown on page 25. The repair parts except for the pull rods and the line-to-ground insulators are the same as for the 34kV switch shown on page 41.

9/10/2020 2:39 PM

Rev . 7


SWITCH CONFIG.

BIL KV (T:T-T:G)

VOLT-AGE

RATING kV

CURRENT RATING A

OPERATING MECHANISM

TYPE

CONTROL VOLTAGE

OUTLINE DRAWING

VES SWITCH

PART NO.

1 POLE 110/200-200 15/34 1000/600 SOLENOID 120VAC 1002860 1002831G1

1 POLE 110/200-200 15/34 1000/600 DOUBLE SOLENOID 120VAC 1002860 1002831G2

The above switch is solenoid operated for use in a laboratory where versatility is an advantage. The switch can be either a 34kV 600A or a 15kV 1000A switch by removing or installing the lower buss bar re-spectively. The double solenoid version of this switch has twice as many solenoids in order to increase the speed of contact closure. This switch contains one form A (e.g., normal open) and one form B (e.g., normal closed) auxiliary contact. The controls for these switches are shown on page 19. The repair parts except for the modules are the same as for the 34kV switch shown on page 41.

SWITCH CONFIG.

BIL KV (T:T-T:G)

VOLT-AGE

RATING kV

CURRENT RATING A

OPERATING MECHANISM

TYPE

CONTROL VOLTAGE

OUTLINE DRAWING

VES SWITCH

PART NO.

1 POLE RH 200-200 34 600 SOLENOID 120VAC 1003377 1003355G1

1 POLE LH 200-200 34 600 SOLENOID 120VAC 1003376 1003354G1

This switch is for switching harmonic filters up to and including the 12th. harmonic. Unlike the Joslyn™ switch of a similar design, the modules on the Vacuum Electric Switch Co.’s harmonic filter switch contain grading capacitors to assure even distribution of the recovery voltage over the three modules. Modules with and without grading capacitors cannot be combined on the same switch and are special for this switch. The switch is solenoid operated. It comes with the buss bars on either the left or right hand sides so that switches connected in parallel on a single phase can be nested together. Having the switches close together makes the current divide more equal between switches connected in parallel. This switch contains one form A (e.g., nor-mal open) and one form B (e.g., normal closed) auxiliary contact. A control for operating this switch is shown on page 21. The repair parts except for the modules are the same as for the 34kV switch shown on page 41.

Right Hand Configuration Left Hand Configuration

9/10/2020 2:39 PM Rev. . 7


Ratings for Vacuum Electric Switches

Design Voltage Nominal/Maximum (kV)

15/15.5 34.5/38 46/48.5 69/72.

5

Continuous current (RMS Amperes)

6005 6005 300 6004, 5 300 300

Fault Interrupting Current (RMS Amperes) Max.

4000 4000 3000 4000 3000 3000

Momentary Current (RMS Amperes, Asymmetric)

20,000 20,000 15,000 20,000 15,000 15,00

0

Frequency (Hz)3 50/60 50/60 50/60 50/60 50/60 50/60

Two-Second Current (RMS Amperes)

12,500 12,500 12,500 12,500 12,500 12,50

0

Four-Second Current (RMS Amperes)

9000 9000 9000 9000 9000 9000

Impulse Withstand, Terminal-to-Terminal (kV) Line-to-Ground (1.2 X 50 Positive Wave)

1101/ 150

2001/ 200

2001/ 200

2001/ 250

2501 2801/ 350

Maximum 60-Cycle Withstand Line-to-Ground (kV) One Minute Dry Ten Seconds Wet

101 74

138 119

138 119

178 176

178 176

245 198

Maximum Peak Inrush Current (RMS Amperes)

20,0002 20,0002 15,0002 20,0002 15,0002 15,00

02

1The terminal-to-terminal BIL is not established by a visible open gap and therefore cannot be used to estab-lish safety clearance for personnel.

2 When switches are used for capacitor bank switching, restrike probabilities are determined by the magnitude

of the in-rush current, the contact open gap, and the contact material. This is explained in a Toshiba paper found in IEEE Transactions on Power Delivery, Vol 10, No. 2 April 1995. Using reactors to reduce in-rush current improves restrike probability. In back-to-back capacitor switching peak cur-rents should be limited by reactors to a switch’s fault interrupting rating. The contact material used in these switches is copper tungsten the same as reported to have the lowest restrike probability in this Toshiba paper. In aged switches with high operation counts, contact welding may occur if the in-rush currents are not limited.

3Switching a harmonic filter requires special considerations. Consult the factory about these applications. 4For capacitor bank switching only, this switch is limited to being used on solidly grounded systems and solidly grounded capacitor banks with currents of less than 200 amperes. 5When switches are used in parallel, the continuous current rating is reduced to 500 amperes to account for unequal current distribution between switches.

9/10/2020 2:39 PM

Rev . 7


Switch Accessories

The 80 ohm resistor module is used to build resistor insertion switches for reducing in-rush currents. It has an arc horn to protect it from over voltages in the event the in-rush current is so large that its with-stand voltage was exceeded. Its VES part no. is: 1002256G1.

The above 30 microhenry reactor is used to limit in-rush current when switching back-to-back (two capacitor banks installed in parallel on the same buss) capacitor banks. It is designed to be installed in place of the buss bar on the 34kV switch shown on page 5. Its VES part no. is: 1002284G1

80 Ohm Resistor Module 30 Microhenry Reactor

Joslyn™ Cable Vacuum Electric Switch Cable

The above cable is for use with a Joslyn™ switch control. The outdoor cable has a cable drip angle. It has either a 15 or 35 pin connector on one end and loose wires on the other for connecting to a terminal strip.

The above cable has a 15 pin connector for connect-ing to a Joslyn switch. The opposite end has a con-nector for connecting to a Vacuum Electric Switch control.

Number of Pins

Length ft. Part No.

15 15 1000775G8

15 20 1000775G2

15 30 1000775G3

15 35 1000775G4

15 40 1000775G5

Number of

Pins

Length ft. Indoor

Part No.

Outdoor Part

No.

15 20 1000415G1 1000576G1

15 25 1000415G4 1000576G4

15 30 1000415G2 1000576G2

35 20 1004504G1 1002156G1

35 25 1004504G2 1002156G2

35 30 1004504G3 1002156G3

9/10/2020 2:39 PM Rev. . 7


Vacuum Switch Service Tool Kit

Vacuum Switch Service Tool Kit: Part No. 1001533G1

Description of Tools in Kit Qty

continuity light box with 4 circuits for synchronizing switches - 1001618G1 1

3° gauge for measuring the maximum link angle - 1001104P1 1

1° gauge for measuring the minimum link angle - 1001104P2 1

0.060”, 0.075”, 0.090” step gauge for setting solenoid nylon pin gap -1001105P1

1

adjustment wedge for synchronizing module contacts - 1001538P1 1

digital dial indicator assembly for measuring mechanism travel and contact over travel - 1001536G1

1

Philips no. 3 screwdriver - 1001673 1

50 in.-lb. torque wrench - 1001541 1

25 in.-lb. torque wrench - 1001539 1

3/8” drive ratcheting torque wrench - 1001671 1

socket, 1/2” 6 pt. 3/8” drive standard - 1001668 1



socket, 7/16” 6 pt. 3/8” drive deep - 1001670 1

box end wrench, 7/16,” 1/2” deep offset - 1001672 1

open end wrench, 3/4” x 7/8” - 1001548 1

9/10/2020 2:39 PM

Rev . 7


Service Parts Kit for VBM™ & VBT™ Switches

Description Part No.

Field service parts kit for Joslyn™ VBT* 15kV switches used for arc furnace switching 1003182G1

Field service parts kit for Joslyn™ VBT* 34kV switches used for arc furnace switching 1003182G2

Switch Service Stand

The above picture shows a switch service stand. When a switch is mounted to the stand, it can be flipped over to work on it right side up or upside down. The field service stand can be purchased either completely as-sembled or as a kit ready for welding. The stand is much easier and less costly to ship as a kit.

Description Kit Part No. Assembled Stand Part No.

Field service stand for a 15 or 34kV switch 1000247G2 1000247G1

Field service stand for a 46 or 69kV switch 1003557G2 1003557G1

This kit was originally designed to meet the Vacuum Electric Switch’s service technician’s parts needs when performing service in a foreign country. One of these parts kits could be shipped ahead of the technician’s arrival, and the technician could be confi-dent that it contained every part that could conceivably be required except vacuum interrupter modules. Companies doing their own service work may find purchasing this kit to be more convenient than ordering parts individually. The kit can be restocked as parts are consumed.

The service parts kit shown to the left is more than enough

parts to service an arc furnace with a total of twelve switches. The difference between the 15kV and 34kV kits are the length of the pull rods supplied. The parts are grouped in individually num-bered boxes and the entire kit is itemized in a spread sheet and in-dexed by description, part number, and its numbered box. The kit is packaged in a Pelican Storm™ case for convenient shipment and storage. An itemized list of the parts in the kit is available on re-quest.

9/10/2020 2:39 PM Rev. . 7


Portable Switch Tester with Scope

The Vacuum Electric Switch portable tester shown above is for dynamically testing a solenoid op-erated switch. The tester contains a capacitor discharge control for operating the switch. Solenoid operated switches may have either one or two closing or opening solenoids requiring either one or two energy storage capacitors respectively to operate the switch. A selector switch selects the number of capacitors for running the test.

The oscilloscope is used to measure both the waveform of the current flowing to the solenoid and also the switch’s opening and closing time. These measurements assure that a switch is properly adjusted. The tester tests the operation of the auxiliary switch circuits.

Sometimes a properly adjusted switch does not operate properly when it is installed. A common cause of such failures is an inadequate supply of current to the solenoids. A current probe is pro-vided so that the oscilloscope can evaluate the waveform and the magnitude of the current flowing in an actual switch installation. Too small of a current or a current which flows for too long a time is indicative of an inadequately powered installation. This test equipment is VES part no. 1004054G1.

9/10/2020 2:39 PM

Rev . 7


The control shown above to the left with two capacitors is for switches having only one closing or opening solenoid. These switches are shown on pages 4, 7, & 12. Switches having two opening and closing solenoids, otherwise known as double solenoid switches, must be operated by the control shown to the right having four capacitors. The double solenoid operated switches are shown on pages 7, 8, & 13. The control circuitry for both controls is identical except that one control has twice as many capacitors.

Single Switch Capacitor Bank Controls

Control Voltage Control Part No.

48VDC 1001820G1

120VAC 1001820G2

125VDC 1001820G3

220VAC 1001820G4


48VDC 1002035G1

120VAC 1002035G2

125VDC 1002035G3

220VAC 1002035G4

Capacitor Bank Switch Controls The capacitor switch controls shown on these pages are different from other controls commonly used

to operate Joslyn™ switches. First, they have extremely low power demands. Second, the control is very precise in timing switch contact opening and closing. Third, the controls are connected to the switches with cables having connectors on both ends to speed installation.

The power demand is low because both the single and multiple switch controls are powered by switch-

ing power supplies with 10 and 25 watts ratings respectively. At these low power levels, the peak current demand is easily under 3 amperes and the maintenance charging current is a trickle. Since the power de-mand is so low, voltage drops in long runs of wire to the control do not cause operating problems. The controls can accept 12VDC, 48VDC, 120VAC, 125VDC, or 220VAC inputs.

These controls are very precise in controlling switching time because the basic electronic circuitry

used in all the controls was designed for closing switches at zero voltage. The precision is achieved both by electronic switching and also having a closely regulated voltage on the stored energy capacitors. The zero voltage switching feature is optional, but even if this option is not elected the precision is retained by the electronics.

The controls are easy to diagnosis and repair. They are a modular assembly of circuit boards, wiring

harnesses, and cables all of which can be quickly unplugged and replaced. This enables a person who is not familiar with the details of the circuitry and operation of the control to quickly isolate and determine what components are not working properly by substituting whole assemblies.

9/10/2020 2:39 PM Rev. . 7


Boost Box Control

Energy Boost Control Box

Joslyn Original Control

Customer Vacuum Switch

Original Switch Cable

Boost Box Cable

The Boost Box Control is designed to assure ade-quate power for reliable operations of specific ap-plications of VBM solenoid operated switches.

Some substation layouts have long distances be-tween the switch and the 120VAC station trans-former or 125VDC battery bank. The unanticipat-ed impedance combined with the high current may result in an excessive voltage drop to the switch. The switch will compensate by taking longer to operate, but occasionally the compensation will be inadequate.

A practical and simple way to offset the undesired voltage drop is with the addition of energy storage capacitors. The Boost Box is inserted in series with the pendant cable going from the existing control to the switch, as seen in the above drawing. The Boost Box contains energy storage capacitors (in blue at left) which are then used to operate the switch. Boost Box:

Internal View

9/10/2020 2:39 PM

Rev . 7


Two Switch Zero Voltage Control

The two switch control shown to the left is for switching capaci-tor banks at zero voltage using the two pole switch along with one sin-gle pole transverse switch shown on page 11.

This control is calibrated using VES calibration test kit part no.

1004054G1, shown on page 18. During calibration test leads are con-nected to the de-energized switch poles to measure the switch timing. A laptop computer with a special program is connected to the control and is used to measure and set the switch timing.

Three Switch Control

The three switch control shown to the left can operate a three phase set of any single pole solenoid operated switch in this catalog except the VBU switch. It can be either a zero voltage or a regular control depending on the firmware installed. The three switches will achieve simultaneous contact closure within 2 milliseconds with mini-mal adjustment effort. The use of this control will substantially reduce the effort required to adjust switches for simultaneous operation when operated on 125VDC.

This control is calibrated using VES calibration test kit part

no. 1004054G1, shown on page 18. During calibration sense leads are attached to the de-energized switch poles to measure their closing times. A laptop computer with a special program is connected to the control and is used to measure the closing time and to set the calibra-tion.

Multiple Switch Capacitor Bank Controls

Control Voltage Control Part No. Control Type

48VDC 1003370G1 Zero Voltage

120VAC 1003370G2 Zero Voltage

125VDC 1003370G3 Zero Voltage

220VAC 1003370G4 Zero Voltage

Control Type Control Voltage Control Part No.

Zero Voltage 48VDC 1003365G1

Zero Voltage 120VAC 1003177G1

Zero Voltage 125 VDC 1003177G2

Zero Voltage 220 VAC 1003177G3

Conventional 48 VDC 1003365G2

Conventional 120 VAC 1003369G1

Conventional 125 VDC 1003278G1

Conventional 220 VAC 1003369G2

9/10/2020 2:39 PM Rev. . 7


Wind Farm Controls

SynchroTeq Control Interface

The wind farm control is used for dynamic VAR compensation at a wind farm. This control can operate three poles of any single pole solenoid operated switch in this catalog except the VBU switch. The control can switch the poles with precision independently of each other at a frequency of every fifteen seconds. The control is powered by 125VDC, and requires a 5kW power source with 3½% maximum impedance. This control’s interface is designed to mate with Vizimax’s SynchroTeq™ control. Its VES part no. is 1004455.

9/10/2020 2:39 PM

Rev . 7


Electric Furnace Controls

This control operates two 15kV 600A three pole switches in a resistor insertion switch arrangement for transient in-rush control. The control first closes one switch through 80 ohm resistor modules. One hundred milliseconds later the control closes a second switch bypassing the resistors.

Induction Furnace Resistor Insertion Switch Control

Arc Furnaces 15kV or 15MVA and Less

Schweitzer™ Relays Can Prevent Catastrophic

This control is for arc furnaces that are operated by one 15kV 600A three pole switch. It is a stored energy control with a fast charging circuit to enable frequent operation of the furnace switch.

The use of this control prevents problems caused by an inade-

quate current source to operate the control. A single solenoid operat-ed switch requires 60 to 65 amperes peak for 1½ cycles to operate properly. If this current is not available, it will operate slowly and may have intermittent malfunctions and failures which are difficult to explain.

Catastrophic switch failures are common on small arc furnaces as a result of a switch’s attempting to interrupt a current exceeding its interrupting rating of 4000 amperes. These failures happen because in an effort to save money, a circuit breaker is not installed in series with the vacuum switch. Over current relays are then connected to the vacuum switch in the absence of the breaker. Since normal switch currents are less than 600 amperes, this arrangement works well most of the time because fault currents are usually less than the vacuum switch’s rating. But occasionally the rating is exceeded, and the result is catastrophic.

The number of failures of this type can be substantially reduced by installing a Schweitzer™ over current

relay as part of the above control. The intelligence in the Schweitzer relay can recognize whether a fault cur-rent is within the capability of the switch. If the current is too large, the Schweitzer relay prevents the vacu-um switch from opening and allows a fuse up stream from the vacuum switch to do the interruption. The pre-vention of a single switch failure will pay for having a Schweitzer relay.


120VAC 1003248G1


120VAC 1003154G1

9/10/2020 2:39 PM Rev. . 7


Number of Switches Per Phase

Control Transformer Control Voltage Control Part No.

1 5kVA at 3.5% max impedance or 10kVA at 7% max impedance

120VAC 1001711G13


120VAC 1001712G13


120VAC 1001713G13

4 20kVA at 3.5% max impedance 120VAC 1001714G13



Arc Furnaces 15 to 46kV and Greater than 15MVA

The control to the left is for an arc furnace with 3000 amperes and primary current at 15kV or 1500 am-peres at 34/46kV. It can operate nine switches total or three per phase. It is a direct replacement for a Joslyn™ arc furnace control. The control shown is representative of a whole range of controls available which are capable of operating from three to eighteen switch mechanisms. The control is modular for easy diagnosis and repair.

This control can minimize transient in-rush current

either with resistor insertion switches or synchronous closing with the alternating current sine wave.

The control is operated by an Allen Bradley™ Mi-

croLogix™ 1100 PLC. The PLC has diagnostics built into its program. The control can detect a switch me-chanical malfunction and initiate an emergency trip so as to prevent single phasing of the furnace transformer. Single phase power on a furnace transformer is a fre-quent cause of exploding arrestors.

The control has a reset function which can reset the

control following an intermittent switch malfunction. This feature enables a furnace to continue operating without down time while deferring the maintenance on switches to a convenient down day.

The MicroLogix PLC has an ethernet connection

for remote monitoring with a PanelView™ monitor. The PanelView™ monitor graphically displays individual switch open or closed status and maintains a date and time stamped log of switch malfunctions which resulted in the control being reset.

9/10/2020 2:39 PM

Rev . 7


Controls for Arc Furnaces Using VBU* Switches

The control above is a direct replacement for a Joslyn™ VBU control. VBU switches shown on page 10 can be used at primary voltages of 69kV to 145kV. They can also be used at 34kV with 2000A and 3000A modules. The control shown operates two VBU poles per phase, but it can be expanded to operating up to five VBU poles per phase.

The control is modular in design for easy diagnosis and repair. A person who does not know all

the details of the control can diagnose problems by substitution. The control is connected to the VBU switch by a cable with a connector on both ends to reduce wiring at installation. An adaptor kit is pro-vided to install a receptacle on each VBU pole.

This control can minimize transient in-rush current either with a resistor insertion switch or by

synchronous closing. The control operates on stored energy for both closing and opening. It is operated by an Allen

Bradley™ MicroLogix™ 1100 PLC which has diagnostics built into its program. The control can de-tect a switch mechanical malfunction and initiate an emergency trip so as to prevent single phasing of the furnace transformer. Single phase power on a furnace transformer is a frequent cause of exploding arrestors.

The control has a reset function which can reset the control following an intermittent switch mal-

function. This feature enables a furnace to continue operating without down time while deferring the maintenance on switches to a convenient down day.

The MicroLogix PLC has an ethernet connection for remote monitoring with a PanelView™

monitor. The PanelView monitor graphically displays individual switch open or closed status and maintains a date and time stamped log of switch malfunctions which resulted in the control being reset.

VBU Poles per Phase

Control Voltage

Control Part No.

1 120VAC 1003223G3

2 120VAC 1003223G1

3 125VAC 1003223G5

9/10/2020 2:39 PM Rev. . 7


Power Requirements for Solenoid Operated Switches

For a solenoid operated switch to operate reliably over time all of the time, the solenoid needs sufficient power so that it completes its stroke for both opening and closing in less than 1½ AC cycles or where powered by DC in less than 20 milliseconds. The peak current draw will be on the order of 60 to 65 amperes or 90 to 130 amperes for switches with single or double solenoids respectively. Sufficient design margin in the current supply is required to compensate for normal variations in the power actually available. The time of solenoid operation is more important than the peak current in determining if the current is adequate.

Switches operating more slowly may operate properly many times but will occasionally malfunction. The malfunctions will be difficult to diagnose. Blowing fuses, emergency trips, solenoid coil failures, exploding arrestors, and an occasional over heating of a module due to a switch not fully closing suggests that the power might be inadequate. The only way to prove that power is inadequate is to measure the time of current flow with a digital oscil-loscope and a current probe. This equipment to perform this test is shown on page 18 and is part of VES’s solenoid switch test kit.

Where switches will be operated in rapid succession as on an arc furnace, they must be supplied by an adequately sized dedicated transformer. When they are only operated occa-sionally as on a capacitor bank, a stored energy control may be used.

Some rules of thumb are required for an adequate power system for a switch installation on an arc furnace. A 5kVA 3½% maximum impedance step-down transformer to 120VAC of transformer capacity is required for each three phase set of switches. Since a 5kVA 3½% impedance transformer is a special order item, an alternative is a 10kVA 7% maximum im-pedance transformer. For arc furnaces, the transformer should be dedicated and located as close as practical to the arc furnace control and be connected by suitably large wire.

In a substation, the station transformer will normally have more than enough kVA capac-ity, but the wire run length from the transformer to the control may be long enough to cause excessive voltage drop. Frequently large wire is installed or even two conductors are con-nected in parallel, but such measures may not always be sufficient. The voltage drop is compounded by the small wire in the switch pendant cable. A Joslyn™ cable has #16 AWG conductors, and long pendant cables on double solenoid switches are especially problematic. At 60 or 120 amperes the voltage drop could be 3.8% and 7.7% respectively. To minimize voltage drop VES cables are made using #14 AWG wire. The voltage drop between the transformer and the control cabinet at the peak current should be held to 3% maximum.

Voltage drop problems for switches installed in substations can be prevented by in-

stalling stored energy controls. A stored energy control contains capacitors to store the ener-gy to operate the switch. When the switch operates, the large current only has to flow the short distance from the control to the switch. Joslyn builds both stored energy and line pow-ered controls. VES only builds stored energy capacitor controls. When a line powered con-trol is discovered to be supplying an inadequate current, the quick solution is to install the VES Boost Box shown on page 20.

9/10/2020 2:39 PM

Rev . 7


Inspection, Testing, and Adjustment of Switches

To Check the Link Angle

1. Start by using 1001104P1 (3 degree measuring tool) or the 1001104P2 (1 degree measuring tool) by placing it on the far end of the handle side of the support bar and against the link-age bar as shown in Figures 3 & 4.

2. The minimal gap between the link and the tool indicates the angle of the link, which corresponds to the angle of the tool.

To Adjust the Link Angle 1. The link angle is controlled by the closing bumper which is one

of two bumpers shown in Figure 5. 2. Mark the position of the closing bumper and then open the

switch. 3. Loosen the two 5/16” bolts that fasten the closing bumper and

move it in a direction to increase or decrease the link angle as required.

4. Re-tighten 5/16” bolts, flip the switch back to the closed position and recheck the link angle.

5. Repeat steps 2-4 until the desired degree link angle is achieved.

Figure 1

Figure 3

Figure 4

Note that the pointer is indicating that the switch is in the closed position

Gap on the Bottom Edge of Setup Tool

Gap on the Top Edge of Setup Tool

Figure 2

Pull Rod Bolts

1. Begin the inspection by recording the switch nameplate and module data. Make copies of the sample forms shown on pages 33 and 34 to aid in recording this data.

2. Close the switch and measure the resistance of all modules using a micro-ohm meter. 3. Open the switch and hi-pot each module using a 30kVAC hi-pot and record the leakage current at 30kV. 4. When doing work on switches, use the bolt torque values shown on page 32. Torque wrenches and tools

for this purpose are contained in the tool kit shown on page 16. 5. Invert the switch, remove the switch cover, and place the switch in the closed position as shown in Figure

1. Place a paper towel or rag in the space between the insulator and pull rod to prevent objects from acci-dentally falling into the module.

6. Measure and adjust the link angle as shown below. Note that the allowable link angles on switches for mo-tor operated or solenoid switches and with regular or double stack modules are different as shown on the inspection record sheets.

7. Measure and adjust the full travel Figure 5.

9/10/2020 2:39 PM Rev. . 7


1. Move the switch to the closed position. Mark the position of the opening bumper.

2. Loosen and move the bumper to increase or decrease the full travel as required. Tighten the bolts.

3. Repeat steps 1 and 2 until the travel is within range.

To Adjust the Full Travel

1. Flip the switch into the closed position and place the dial indicator gauge near the far end by the bumper block as shown in Figure 5.

2. Zero the dial, flip switch to the open position, and record the dial read-ing. A properly adjusted switch has full travel between 0.200” and 0.210” as shown in Figure 8.

To Check the Full Travel

Figure 5

0.185” is not in Range of Full Travel

Switch is in the Open Position

Dial Indicator Placement

Zero Reading

Closed Position Position Mark

Figure 6 Figure 7

Position Marks

0.205”+/-.005” Full Travel

Figure 8

To Check the Synchronism Between Vacuum Bottles

1. Hook any type of continuity device (light box, ohm meter, beeper box, or etc.) to the top (red lead) and bottom (black lead) terminal pad of each module.

2. Flip switch to the closed position and zero the dial indicator. 3. Place a 3/4” open end wrench on the center link, and pull the switch

open while noting the dial indicator reading for each module at mo-ment at which continuity is lost. It should be between 0.036” and 0.044” for a properly adjusted switch.

3/4” Wrench Direction to Open

Continuity Device

Figure 9

To Adjust Contact Synchronism

1. With the switch in the closed position loosen all pull rod bolts as shown in Figure 2.

2. Force the adjustment wedge (1001538P1) between the closing bumper block and housing until the dial indicator reads 0.040”+/-.004” as shown in Figure 10.

3. Insert and tighten the pull rod bolts and then remove the wedge. 4. Measure and record the sync of each module the same as in step 3 above. 5. Repeat steps 1-4 until all modules loose continuity between 0.036” and

0.044” of travel.

Figure 10

Adjustment Wedge

Note Needle is Half Way Between Open and Close

9/10/2020 2:39 PM

Rev . 7


To Check the Auxiliary Switch Travel

Adjustments for Solenoid Operated Switches Only

1. Place the switch in the closed position, zero the dial indicator, and clamp the operating handle to the handle cover with a c-clamp so that the handle does not move.

2. Apply a 3/4” open-end wrench to the center link and open the switch by moving the wrench away from the solenoid.

3. Listen for a click sound indicating the Eaton™ auxiliary switch has changed state. It should change state before 0.175” of travel.

4. Record the dial indicator reading at the change of state. 5. Once the click is heard, return the wrench to its starting position while

listening for a click again. It should change state again before the trav-el decreases to 0.025”.

6. Record the dial indicator reading at the second change of state. 7. The auxiliary switch must change state before 0.175” on opening and

again before 0.025” on closing.

Switch in Open Position

Figure 11

3/4” Wrench Direction to open

Zero Reading

To Adjust the Auxiliary Switch Travel

1. With the switch in the closed position, mark a line on the support bar to indicate the position of the auxiliary switch mounting bracket.

2. Slightly loosen the two 1/4-20 bolts, move the bracket to the desired po-sition, and retighten screws as shown in Figure 12.

3. Check the auxiliary switch travel by repeating steps 2-5 above. 4. Repeat the readjustment until the auxiliary switch changes state before

0.175” on opening and 0.025” on closing.

To Check and Adjust Solenoid Pin Gap

1/4-20 Bolts Position Mark

Eaton Auxiliary Switch

Figure 12

1. Place the switch in the closed position and measure pin gap for the opening solenoid by sliding thickness gauges between the nylon and metal pins as shown in Figure 13.

2. Place the switch in the open position and similarly measure the pin gap for the closing solenoid. 3. The pin gaps must be between 0.060” and 0.090”. 4. To adjust the gap remove solenoid assembly mounting bolts one at a time and add or remove shims

(1000754P1) between the solenoid mounting plate and the zinc plated spacers. This gap controls switch speed. Larger and smaller gaps increase or decrease switch speed respectively.

Figure 13

Mounting Plate

Nylon Pin

Zinc Plated Spacer

Metal Pin

9/10/2020 2:39 PM Rev. . 7


Maintenance of Motor Operated Switches

Motor operated switches have the same modules, pull rods, and linkages as the solenoid operated switch-es. Except for the link angle, the full travel and over travel adjustments are made in the same manner as for the solenoid operated switch. The link angle is set at 1 degree for a motor operated switch. The larger link angle used for a solenoid operated switch will cause the switch to immediately trip open following closing.

Motor operated switches are different from the solenoid operated switches in that the energy to open and close the switch is supplied by the motor operator mechanism. Relatively weak extension springs are installed between the toggle link and the control yoke instead of the heavy compression springs used with the solenoid operated switches.

The operation of the switch handle or the motor does not directly change the switch’s state from open to closed, but its action charges a spring which then is used to open or close the switch. Motor operator switches can operate on different voltages which are determined by what relay panel is installed in the switch along with which field jumpers are installed. The relay panels and required jumpers are shown on pages 36-38.

The four major assemblies which distinguish the motor from the solenoid operated switch are:

1. Motor Mechanism - this mechanism consists of links, levers, shafts, and springs all held together by two side plates. This whole mechanism is somewhat like a clock mechanism and is difficult to disassemble and reassemble. Purchasing a remanufactured motor mechanism assembly is an easier alternative to disas-sembling and reassembling a motor mechanism. The part number of the motor mechanism without the motor assembly is 1002673G1. The four parts in the motor mechanism which commonly fail consist of the side plates, the trip link, the boomerang levers, and the spring bolts. VES has redesigned all of these parts to pre-vent failure. The amount of work to disassemble and reassemble the motor mechanism is so intensive that if any one of these parts is replaced, all of these potential failure parts should also be replaced to avoid subse-quent failures.

2. Motor Assembly - Removal and replacement of the motor assembly is comparably easy. The mo-tor assembly consists of a universal 48VDC electric motor, worm gear, speed reducing worm wheel, and cams to drive the ratcheting clutches in the motor mechanisms. Occasionally 24VDC motors are used in place of the 48VDC motor. Frequent failures which occur are worn worm wheel and shaft bearing journals. The VES Co. has redesigned the motor assembly to extend its life by changing materials and adding lubrication. The VES Co. motor assembly part no. is 1002399G1.

3. Relay Panel - the relay panel is mounted on the side of the motor mechanism, and it determines the operating voltage of the switch. Having the wrong relay panel installed or the wrong jumpers selected for the applied control voltage is a common cause of resistor burn out and motor failure. Many different relay panels exist. The three most common are shown on pages 36-38. Relay panels can be easily changed.

4. Wiring Harness - Wiring harnesses are available with 15 or 35 pin connectors. The connector with more pins offers more auxiliary contacts for customer connections. These are moderately difficult to re-place because of the large number of wires.

5. Auxiliary Switches - Several different types of auxiliary switches have been used with Joslyn™ motor operated switches. Vacuum Electric Switch Co.’s contact block has the foot print and functionally of the original block and uses Allen Bradley™ contacts, housing, and yoke. The Allen Bradley contacts are easi-ly replaceable. Anyone contemplating replacing an auxiliary switch should call to discuss their switch’s com-patibility with the Allen Bradley contact block replacement.

9/10/2020 2:39 PM

Rev . 7


Instructions for Motor Operated Switches Only

To Check the Motor Mechanism

To Adjust the Motor Mechanism

1. Start with the switch in the open position, and unscrew the 2. 1/4-20 trip screw (1002415) until it is retracted into the mid-

dle linkage (1002031P1) and screw in the 3/8-16 stop bolts (1000480) until the heads are touching the side plate ears as shown in Figure 15.

3. Crank the handle 20-35 times until the switch closes, advance the stop bolts until they are 0.010” to 0.020” from the shaft, and then tighten the jam nut to hold in place.

4. Screw in the trip screw until the switch opens, then back it off 1 to 1½ turns, and tighten the jam nut to hold it in place.

5. Repeat steps 1-3 until the switch can be operated by the han-dle alone. Finally apply a small amount of thread locker on both the trip screw and stop bolts.

To Check the Allen Bradley™ Contact

1. With the switch in the open position, use a continuity device to determine aux switch state. Flip the switch to the closed posi-tion and determine that the aux switches have changed state.

2. If contacts do not change state, adjust mounting bracket to cor-rect.

To Adjust the Allen Bradley™ Contacts

1. With the switch in the open position, draw a line on the sup-port bar as shown in Figure 16.

2. Slightly loosen the mounting bolts and adjust aux switch. 3. Recheck with the continuity device. 4. Repeat steps 1-3 until all aux contacts fully open and close

when the switch changes state.

Trip Screw

Stop Bolt

Figure 15

Open Position Motor Mechanism Mini-cams

Figure 14

Handle Allen Bradley Contact Blocks

Large Springs

Marking Line Motor Toggle Spring

Mounting Bolts

Figure 16

1. Position the mini cams on the motor assem-bly to a vertical position. Measure the large springs to verify they are 3” to 3.125” long.

2. Crank the handle of the switch 20-35 times until the switch flips to the closed position. Then slap the handle to trip the switch into the open position. If the switch cannot be changed to the open or closed state, the mechanism needs adjustment.

9/10/2020 2:39 PM Rev. . 7


Fastener Torque Requirements

9/10/2020 2:39 PM

Rev . 7


Name Plate Data

VBT™ Serial Number

Cat. No.

Continuous Current Rating (AMPS)

kV Rating

G.O. No.

Terminal-to-terminal BIL (kV)

Terminal-to-ground BIL (kV)

Recorded Switch Data

Module Data

Left Center Right

Manufacturer

Module Serial No.

Vacuum Interrupter Serial No.

Sync - normal 0.040” ± 0.004

Resistance micro ohms - normal less than 200

Hi-pot - current normal 1mA or less at 30kV, reject at greater than 2mA

Mechanism Data

1500VAC control wiring test

Link angle - 1 to 3 degrees toward opening for solenoid operated switch, 1 degree for a motor operated switch

Full travel - normal 0.200” to 0.210”

Switch counter reading

Auxiliary Switch

Aux switch adjustment - operate before 0.175” of mechanism travel on opening and before 0.025” on closing

Form A (no) contacts 1, 2, or 6

Form B (no) contacts 1, 2, or 6

Solenoid

Pin gap adjustment of nylon pins for open and close coils - normal is 0.060” to 0.090”

Motor Operator

Number of handle cranks to closing: 20 to 35 times is normal

Slap handle once to open switch: ok or reject

Time for motor to run to close: 3 sec. for AC, 5 sec. for DC control voltages

Electrical trip: ok or reject

Data Recording Sheet for Switches with Regular Modules

9/10/2020 2:39 PM Rev. . 7


Name Plate Data

VBT™ Serial Number

Cat. No.

Continuous Current Rating (AMPS)

kV Rating

G.O. No.

Terminal-to-terminal BIL (kV)

Terminal-to-ground BIL (kV)

Recorded Switch Data

Module Data

Left Center Right

Double stack modules upper lower upper lower upper lower

Manufacturer

Module Serial No.

Vacuum Interrupter Serial No.

Resistance micro ohms - normal less than 200

Hi-pot - normal 1mA or less at 30kV, re-ject at greater than 2mA

Sync - normal .040” ± .004

Mechanism Data

1500VAC control wiring test

Full travel - normal 0.200” to 0.210”

Link angle - 1 degree toward opening

Switch counter reading

Auxiliary Switch

Aux. switch adjustment - operate before 0.175” of mechanism travel on opening and before 0.025” on closing

Form A (no) contacts continuity 1, 2, or 6

Form B (no) contacts continuity 1, 2, or 6

Solenoid Data

Pin gap adjustment of nylon pins for open and close coils - normal is 0.060” to 0.090”

Motor Operator Data

Number of handle cranks to closing: 20 to 35 times is normal

Slap handle once to open switch: ok or reject

Determine motor operator control voltage by inspecting relay panel

Motor run time to close: 3 sec. for AC, 5 sec. for DC control voltages

Electrical trip: ok or reject

Data Recording Sheet for Switches with Double Stack Modules

9/10/2020 2:39 PM

Rev . 7


Th

is s

chem

atic

is

of

the

wir

ing h

arnes

s in

so

leno

id o

per

ated

sw

itch

es. T

he

ph

oto

gra

ph

to

th

e le

ft i

s o

f th

e E

aton™

sw

itch

dep

icte

d i

n

this

sch

emat

ic. O

ver

a fi

fty y

ear

tim

e in

terv

al, th

e E

ato

n s

wit

ch i

s o

ne

of

sever

al d

iffe

rent

aux

ilia

ry s

wit

ches

whic

h w

ere

use

d. T

he

V

acuu

m E

lect

ric

Sw

itch

Co. m

anufa

ctu

rers

a r

epla

cem

ent

wir

ing h

arnes

ses

usi

ng t

he

Eat

on™

sw

itch

.

So

len

oid

Op

era

ted

Sw

itch

es

P

N

G

A

M

D

J H

C

B

L

R

Aux

ilia

ry S

wit

ch

Open

Coil

C

lose

d C

oil

R

E

B

G

L

F

K

D

E

L

F

R

M

N

J C

H

A

P

PA

Sw

itch

Wir

ing

Sch

ema

tics

9/10/2020 2:39 PM Rev. . 7


A m

oto

r oper

ated

sw

itch

, w

ith t

he

rela

y p

anel

show

n t

o t

he

left

, oper

ates

on 4

8V

DC

or

120V

AC

. T

he

rela

y p

anel

can

be

iden

tifi

ed b

y

its

two r

esis

tors

, one

fix

ed a

nd t

he

oth

er a

dju

stab

le. T

he

abov

e sc

hem

atic

show

s both

the

cust

om

er a

nd i

nte

rnal

sw

itch

wir

ing f

or

op-

erat

ing t

he

swit

ch o

n 4

8V

DC

. T

wo f

ield

inst

alle

d j

um

per

s ar

e re

quir

ed a

s sh

ow

n i

n t

he

schem

atic

.

Mo

tor

Op

era

tor

48

VD

C

9/10/2020 2:39 PM

Rev . 7


A m

oto

r oper

ated

sw

itch

, w

ith t

he

rela

y p

anel

show

n t

o t

he

left

, ca

n b

e oper

ated

on 4

8V

DC

or

120

VA

C. T

he

rela

y p

anel

can

be

iden

-ti

fied

by i

ts t

wo r

esis

tors

, one

fix

ed a

nd t

he

oth

er v

aria

ble

. T

he

above

schem

atic

show

s both

the

cust

om

er a

nd i

nte

rnal

sw

itch

wir

ing

for

oper

atin

g t

he

swit

ch o

n 1

20V

AC

. O

ne

fiel

d i

nst

alle

d j

um

per

is

requir

ed a

s sh

ow

n i

n t

he

schem

atic

.

Mo

tor

Op

era

tor

12

0V

AC

9/10/2020 2:39 PM Rev. . 7


A m

oto

r oper

ated

sw

itch

, w

ith t

he

rela

y p

anel

show

n t

o t

he

left

, is

oper

ated

on 1

25V

DC

. T

he

rel

ay p

anel

can

be

iden

tifi

ed b

y i

ts t

hre

e re

sist

ors

. T

he

thir

d r

esis

tor

is v

isib

le b

ehin

d t

he

oth

er t

wo. T

he

above

sch

emat

ic s

how

s both

the

cust

om

er a

nd i

nte

rnal

sw

itch

wir

ing t

o

oper

ate

the

swit

ch o

n 1

25V

DC

. T

wo j

um

per

s in

stal

led i

n t

he

fiel

d a

re r

equ

ired

as

show

n i

n t

he

sch

emat

ic.

Mo

tor

Op

era

tor

12

5V

DC

9/10/2020 2:39 PM

Rev . 7


Joslyn™* Switch Cable Color Codes

The thirty-five pin connector is only used with motor operated switches. The color code and function of the first fifteen conductors in the thirty-five pin connector are identical to the colors and functions of the conductors of the fifteen pin cable. The cable cost for the thirty-five conductor cable is about six times as expensive as the fifteen conductor cable. Where only the first fifteen conductors are being used, money can be saved by ordering a thirty-five pin connector with the fifteen conductor cable attached.

Thirty-Five Pin Connector Cable Color Codes

Fifteen Pin Connector Cable Color Codes

9/10/2020 2:39 PM Rev. . 7


Vacuum Breaker Up-right Switch Parts

The new VBU module has part no. 1002719G2 is shown in the picture to the right. The drawing to the left shows how the Mitsubishi vacuum interrupter is installed in the module.

The VBU mechanism above, VES part no.1004429G1, has been reverse engineered and remanu-factured to be like the original Joslyn™ mechanism design. The adjustment cams have been reincorpo-rated the same as in the original design. The cam can be seen in the above picture. The Square D™ con-tact blocks shown in the schematic above have been replaced with Allen-Bradley™ contactors as shown in the center above. They are mounted on the side of the VBU mechanism as shown to the above right. Needle bearings in this mechanism frequently failed. They have been replaced with oil impregnated bronze sleeve bearings because they are better under shock loading. The needle bearings in the trip link-ages have been replaced with glass filled Teflon bearings because they have very low static friction. Too much static friction can cause the trip link to not reset following a trip operation.

When VBU switches are used on arc furnaces, the causes of down time can be categorized as be-

ing attributed to modules, operating mechanisms, and controls. Design changes in remanufactured mod-ules have eliminated almost all routine failures in modules. Design changes in the reverse engineered mechanism above have enabled that mechanism to exceed 75,000 operations in life testing. The control problems have been addressed by the control shown on page 25. Diagnostics are part of this control’s program. This control is an adaptation of the control on page 24, for which there are more than twenty installations.

9/10/2020 2:39 PM

Rev . 7


Switch Replacement Parts

15kV 600 Ampere Three Pole Vacuum Switch

34kV or 46kV 600 Ampere Single Pole Vacuum Switch

9/10/2020 2:39 PM Rev. . 7


46kV 300 Ampere Single Pole Vacuum Switch

9/10/2020 2:39 PM

Rev . 7


69kV 300 Ampere Single Pole Vacuum Switch

9/10/2020 2:39 PM Rev. . 7


34kV 300 Ampere Three Pole Vacuum Switch

9/10/2020 2:39 PM

Rev . 7


Exploded DECCO™ Solenoid and Associated Installation Parts

Housings and Solenoids

Mechanism for 15kV or 34kV Single Pole and 46kV or 69kV Switch

9/10/2020 2:39 PM Rev. . 7


Exploded NAMCO™ Solenoid and Associated Installation Parts

Mechanism for 15kV or 34kV Single Pole and 46kV or 69kV Switches with NAMCO™ Solenoids

9/10/2020 2:39 PM

Rev . 7


Bumper Assembly Section G-G

Cross Section Details from Views on Pages 45 & 46

Section C-C Section E-E

Sections D-D & F-F

9/10/2020 2:39 PM Rev. . 7


JOSLYN ™ Design of Control Yoke Assembly (w/cast steel handle & 1/2” shaft)

VES New Control Yoke Assembly (w/machined aluminum handle & 3/4” shaft)

Section A-A Section B-B

Section A-A Section B-B

9/10/2020 2:39 PM

Rev . 7


Six Digit Counter & Position indicator

Five Digit Counter

Counters and Position Indicators

The three different types of counters which have been used in manufacturing the VBM switch include a counter attached to the manual operating handle cover, the internal five digit counter, and the externally visible six digit counter. The five and six digit counters are shown above. The handle cover counter is not available.

Five-Digit to Six-Digit Position Indicator Counter Conversion

During switch overhauls at the Vacuum Electric Switch Co.™, old switches without ex-ternally visible counters are modified to use the new externally visible six digit counter with a position indicator. This upgrade makes it easier to track switch operations for purposes of sched-uling maintenance. The modification can only be done in the shop because it requires welding in a boss and re-machining the switch mechanism casting. The window for the new counter and po-sition indicator is sometimes located where the existing name plate is located. In this instance, the Vacuum Electric Switch Co. replaces the old name plate with a new name plate having the old serial number.

9/10/2020 2:39 PM Rev. . 7


Mechanism for 34kV Three Pole Switch with DECCO™ Solenoids

Linkage Assemblies for a 34 kV Three Pole Switch with Removed Parts Shown in Phantom

9/10/2020 2:39 PM

Rev . 7


Mechanism Housing for 34kV Three Pole Motor Operator Switches

Section H-H Section J-J Section L-L

Section N-N Section K-K

9/10/2020 2:39 PM Rev. . 7


Mechanism Housing for 15kV Three Pole Motor Operator Switches

Section J-J Section L-L

Section K-K Section M-M

9/10/2020 2:39 PM

Rev . 7


Motor Operator Rear Mounting Bracket Assembly

Motor Operator Standard Motor Assembly

9/10/2020 2:39 PM Rev. . 7


Motor Operator Left Side Motor Plate Assembly

9/10/2020 2:39 PM

Rev . 7


Motor Operator Right Side Motor Plate Assembly

9/10/2020 2:39 PM Rev. . 7


Toggle Link Components in Motor Mechanism Assembly

Clutch Arm Cam Motor Mechanism Assembly

9/10/2020 2:39 PM

Rev . 7


Replacement Parts for Joslyn™ Controls

Joslyn SCR Board VES Replacement SCR Board

Joslyn Timing Board VES Replacement Timing Board

The two Joslyn™ circuit boards shown above are used by Joslyn in both their zero-voltage con-trol for capacitor banks and also their Point-of-Wave™ controls for arc furnaces. Shown opposite the Joslyn boards are the Vacuum Electric Switch’s foot-print and plug-for-plug compatible replacement board. The SCR boards are functionally equivalent except that the VES board (part no.1002100G1) has transient suppression components on the board whereas the Joslyn board requires that they be installed at the terminal connections during the board installation. While functionally equivalent, the timing boards are designed using different concepts. The Joslyn timing board has analog circuitry to control the timing. The timing adjustments are made by turn-ing three trip potentiometers on the board. The Vacuum Electric Switch timing board has digital circuit-ry. The timing is controlled with crystal oscillator, and the switch timing can be digitally set in incre-ments of 25 microseconds. The VES digital board has an RS232 connection which can be connected to a computer and used to measure and set switch timing.

VES Timing Boards

Voltage VES part No.

120VAC 1002121G1

125VDC 1002121G2

24VDC 1002121G4

9/10/2020 2:39 PM Rev. . 7


Replacement Parts List

Item No. Description Joslyn™ Part No.

VES™ Part No.

1 Mechanism assembly, 15kV solenoid operated three pole switches 3021X0242 P001

1A Mechanism assembly, 34, 46, & 69kV solenoid operated two pole switches

1B Mechanism assembly 34kV solenoid operated three pole switches

1C Mechanism assembly 34kV motor operated three pole switches

1D Mechanism assembly 15kV motor operated three pole switches

2A Fracture resistant vacuum interrupter module, 15kV 600A without pull rod 3021X0242 P003 1000674G1

2B Fracture resistant vacuum interrupter module, 34kV 600A without pull rod 3021X0242 P005 1000674G1

2C Fracture resistant vacuum interrupter module, 46kV 600A without pull rod 3021X0242 P007 1000674G1

2D Double stack module, silicone rubber sheds, 300A 3021X0242 P401 1001184G1

2E Single module with silicone rubber sheds, 300A 1001989G1

2F Double stack module for 46 & 69kV 300A switch 3021X0242 P401 1001184G6

2G Module with grading capacitors, 34kV 600A, without pull rod

2H Single module with grading capacitors and silicone rubber sheds, 300A for 46kV switch

2I Double stack module with grading capacitors and silicone rubber sheds, 300A for 46 & 69kV switch

2J Double stack module with grading capacitors and silicone rubber sheds, 300A for 34kV three pole switch

3 Bolt, hex head, 1/4-20 x 2½" SST 3021X0242 P008 1000587

3A Bolt, hex head, 1/4-20 x 2" SST 1001242

3B Bolt, hex head, 1/4-20 x 1" SST 1001225

3C Bolt, hex head, 1/4-20 x 1½" SST 1000120

4 Washer, Belleville SST 3021X0242 P009 1000640

5 Washer, flat, 9/32 ID x 5/8" OD x 1/16" alum. 3021X0242 P010 1000635

6 Gasket, obsolete 3021X0242 P011

7 Nut, hex, 1/4-20 SST 3021X0242 P012 1000583

8 Insulator, 15kV, skirted 3021X0242 P014 1000662

9 Bolt, hex head, 1/4-20 x 1¼" SST 3021X0242 P015 1000106

10 Bolt, hex head, 1/4-20 x 1¼" L, Gr. 8 3021X0242 P016 1000601

10A Bolt, hex head, 1/4-20 x 1" L, Gr. 8 1000018

11 Washer, split lock, 1/4" standard, Gr. 5 & 8 3021X0242 P017 1000008

11A Washer, SAE flat, 1/4" 1000013

12 Nut, hex head, 1/4-20 standard, Gr. 8 3021X0242 P018 1000027

13 Obsolete

14 Mechanism gasket, 10 hole D63293P1 1000107P1

14A Mechanism gasket, 12 hole 3021D0422P1 1000107P2

15 Mechanism cover, 10 hole 3021X0242 P021 1000568P1

15A Mechanism cover , 12 hole 1001809P1

Delivery Color Code Red: Orders received before 12:00 PM EST will ship the same day. Green: Ship date three business days after receipt of order. Blue: Ship date ten business days after receipt of order. Black: Ship date determined at order placement.

9/10/2020 2:39 PM

Rev . 7



VES™ Part No.

16 Screw, pan head, Phillips, 1/4–20 x 1" SST 3021X0242 P022 1000595

17 Washer, split lock, 1/4" standard, SST 3021X0242 P023 1000110

18 Screw, indented hex head, 6-32 x 3/8" L, SST 3021X0242 P024 1000931

19 Drierite™ desiccant, 2 oz. calcium sulfate in sealed bag 3021X0242 P025 1000924

20 Bolt, hex head, 3/8-16 x 1" L 3021X0242 P026 1000111

21 Washer, split lock, 3/8" standard 3021X0242 P027 1000112

22 Closure plate 3021X0242 P101 1001996P1

23 Clamping plate, 1/4-20 tapped hole (use with parts 10A & 11) 3021X0242 P102 1000644P1

23A Clamping plate, 3/8-16 tapped hole (use with parts 20 & 21)

24 Breather bag 3021X0242 P103 1000114P1

24A Sheet metal shroud covers breather bag 3021D0113P2 1000580P1

24B Valve, Schrader 1000534

24C Screw, pan head, 1/4-20 x 5/8" plastic, black 1000414

24D Bolt, hex head, 1/4-20" x 1/2" SST 1001821

24E Washer, flat, 1/4" ID x 1/2" OD, SST 1001823

25 Screw, slotted head, 10-32 x 3/8" L, SST 3021X0242 P104 1000507

26 Handle cover with three screw holes 3021X0242 P105 1000578P2

26A Handle cover with two screw holes 1000578P3

26B Counter for handle cover, 5 digit 1000925

27 Mechanism assembly 34 & 46kV 3021X0242 P106

28 Bolt, hex head, 1/2-13 x 1¼" L, SST 3021X0242 P107 1000029

29 Washer, Belleville, 1/2" SST 3021X0242 P108 1000055

30 Nut, hex, 1/2-13 standard, SST 3021X0242 P109 1000030

30A Washer, flat, 1/2" thick SST 1000054

30B Noalox™ 8 oz. 1000021

30C Connecting bar for 34kV harmonic filter switch 1000544P1

30D Connecting bar for 46kV double stack switch 1001983P1

31 Connecting buss bar for 34, 46 & 69kV 600A switches 3021X0242 P110 1000508P2

32 O-ring, 3½" ID x 3¾" OD x 1/8", dash 238 3021X0242 P111 1000638

33 Insulator, 34kV skirted 3021X0242 P112 1000661

33A Insulator, 46kV skirted 3021X0242 P113 1001940

34 Bolt, hex head, 1/4-20 x 1¾" L, SST 3021X0242 P114 1000684

35 Gasket, Teflon 3021X0242 P115 1000121P1

36 Mechanism housing for 15kV or 34kV three pole 3021X0242 P116 1000564P1

37 Mechanical housing for 34, 46, or 69kV two hole 3021X0242 P117 1000563P1

38 Control yoke 3021X0242 P118 1000500P2

38A Washer, Nylatron, 1/2" ID x 0.031" 1000610

38B Washer, Nylatron, 1.125" OD x 0.753" ID x 0.030" thick 1002080

38C Control yoke, 3/4” 1002068P1

39 Nylon pin 3021X0242 P119 1000376P1

40 Dust cap 3021X0242 P120 1000124

41 Connector, obsolete 3021X0242 P121

9/10/2020 2:39 PM Rev. . 7



VES™ Part No.

42 Pull rod, clevis 3021X0242 P122 1000023G1

42A Pull rod, clevis, for handle side of 34kV three pole switch 1001125G1

42B Pull rod, clevis, for position indicator counter side of 34kV 300A three pole switch

1001122G1

42C Clevis shaft for use with 42A & 42B 1001121P1

43 Bolt, hex head, 3/8-16 x 2¼" L, Gr. 8, SST 3021X0242 P123 1000602

43A Bolt, hex head, 3/8-16 x 2½" L, Gr. 8 1000997

43B Washer, split lock, 3/8", Gr. 8 1000112

43C Screw-lock, helical, 3/8-16 (used with 43A) 1000012

44 Actuator bar link 3021X0242 P124 1000514G1

44A Actuator bar link for 34kV three pole switch 1001119G1

45 Actuator bar without screw holes for aux switch plate 3021X0242 P125 1000513G1

45A Actuator bar with screw holes for aux switch actuator plate 3021X0242P125 1000513G2

46 Support bar with mounting holes for Eaton™ aux switch 3021X0242 P126 1000512G1

46A Support bar for 34kV 300A three pole switch 1000512G2

47 Ty-wrap 3021X0242 P127 1000607

48 Bolt, hex head, 3/8-16 x 1¾" L, obsolete 3021X0242 P201

49 Nut, hex, standard, obsolete 3021X0242 P202

50 Solenoid assembly, DECCO™ 3021X0242 P203 1000685G1

50A Solenoid coil, DECCO™ 3021B0511 P7 1000515P15

50B Plunger, DECCO™ (replace as matched set with 50C) 1000515P7

50C Push pin, DECCO™ (replace as matched set with 50B) 1000515P13

50D Side plate, DECCO™ (replace all four at one time) 1000515P3

50E Solenoid spacer for 1/4" hex cap screw, DECCO™, 1/2" dia. x 1¼" L 1000502P1

50F Screw, hex cap, 1/4-20 x 2", Gr. 5 1000603

50G Washer, shim, 1/4" ID, 0.010" thick, brass 1000745P1

50H Field stack, DECCO™ 1000515P2

50J Screw 1000515P4

50K Nut, Nylock 1000515P5

50L Washer, lock 1000515P6

50M Spring 1000515P8

50N Stop plate 1000515P9

50P Shock absorbers 1000515P10

50Q Mounting pad 1000515P11

50R Solenoid shim 1000705

50S Bushing 1000515P14

50T Vibra-Tite Formula 3™ thread locker 1000074

50U Solenoid coil, NAMCO™ EB401-78093 1000539

50V Bearing plate, NAMCO™, bronze 1000810P1

50X Bearing plate support, right , NAMCO™ 1000813P1

50W Bearing plate support, left, NAMCO™ 1000812P1

50Z Coil clip, NAMCO™ 1000811P1

9/10/2020 2:39 PM

Rev . 7



VES™ Part No.

50AA U shim, switch solenoid 0.020" 1000320P1

50AB U shim, switch solenoid 0.031" 1000320P2

50AC U shim, switch solenoid 0.040" 1000320P3

50AD Field stack, NAMCO™

50AE Armature, NAMCO™

50AF Top plate, NAMCO™

50AG Stand off (short)

50AH Stand off (long)

50AJ Screw, socket head cap

50AK Screw, hex head, 1/4-20 x 4" L, Gr. 8 1000768

50AL Solenoid assembly, NAMCO™

50AM Double solenoid, DECCO™, for 34kV 300A three pole switch 1001156G1

51 Yoke bumper stop (all rubber) for DECCO™ solenoid only 3021X0242P204 1000516G1

51A Yoke bumper stop (all rubber) for NAMCO™ solenoid only 1000932G1

51B Yoke bumper stop (all rubber) for DECCO™ double solenoid only 1001066G1

52 Expansion plug, aluminum 3021X0242 P205 1000158

53 Bushing, 1/2" ID x 5/8" OD x 3/4" L 3021X0242 P206 1000385

54 Shaft (short) 1/2" dia. 3021X0242 P207 1000511P1

55 Bushing, 1/2" ID x 5/8" OD x 1" L 3021X0242 P208 1000609

56 Seal for 1/2" dia. shaft 3021X0242 P209 1000386

56A Seal, spring loaded double lip, for 3/4" dia. shaft 1002064

57 Shaft (long) 1/2" dia. 3021X0242 P210 1000510P1

57A Shaft (long) 3/4” dia. 1002062P1

58 Actuating arm, Joslyn™ design for 1/2" dia. shaft 3021X0242 P211 1000498P2

58B Operator handle, 0.5" dia. shaft 1002063P1

59 Pin, Sel-lock, 1/4" dia. 3021X0242 P212 1000051

59A Spring pin, 3/8"dia. x 1½" 1002289

59B Spring pin, 3/8" dia. x 2" 1002288

60 Cotter pin, (Monel) 1/8" x 1½" 3021X0242 P213 1000681

60A Cotter pin, 1/8" x 2 L, zinc plated steel 1002147

61 Washer, flat, 0.156" ID x 0.375" OD x 0.036-.065" thick 3021X0242 P214 1000730

61A Washer, 0.438" OD x 0.188" ID, 18/8 SST 1002590

62 Lockwire, 0.032 dia., 1/8 hard, 303 SST 3021X0242 P215 1000387

63 Cotter pin, (Monel) 1/16" x 1/2" 3021X0242 P216 1000446

64 Washer, Nylatron spacer, 0.062" thick 3021X0242 P217 1000098

65 Washer, Nylatron spacer, 0.015" thick 3021X0242 P218 1000096

65A Washer, Nylatron spacer, 0.032" thick 1000097

66 Toggle link 3021X0242 P219 1000499G1

67 Plain bearing, 1/4" x 3/8" x 1/4" L 3021X0242 P220 1000002

68 Link pivot pin (short) 1/4" dia. 3021X0242 P221 1000057P1

69 Clevis pin, spring retaining 1/8" dia. x 7/8" 3021X0242 P222 1000024P3

69A Washer, wool felt, 0.062" thick 1000725

9/10/2020 2:39 PM Rev. . 7



VES™ Part No.

69B Washer, wool felt, 0.125" thick 1000724

70 Spring assembly for 15, 34, 46kV 600A switch and 46 & 69kV 300A switch 3021X0242 P223 1000390G1

70A Spring assembly for 34kV 300A three pole switch 1000390G2

71 Clevis pin, 1/4" dia. 3021X0242 P224 1000058P1

71A Locking plate, 1.25" x 0.0625" x 0.125" 1000606P1

72 Bolt, hex head, 1/4-20 x 3/4", Gr. 8 3021X0242 P225 1000391

73 Washer, flat, 1/4" nom. x 9/16" OD, zinc plated steel 3021X0242 P226 1000392

74 Wire harness, Eaton™ auxiliary switch, & environmental connector w bracket & crimp connectors on wires

3021X0242 P227 1000521G1

75 Plate, switch actuating 3021X0242 P301 1000530P1

75A Screw, slotted round head, 6-32 x 3/8" L 1000460

75B Washer, internal tooth, #6 1000604

75C Loctite 290™, green 1000605

76 Screw, Fillister head 3021X0242 P302 1000395

77 Washer, split lock, standard, #6 3021X0242 P303 1000594

78 Gasket (receptacle) 3021X0242 P304 1000148P1

79 Spacer 3021X0242 P305 1000398

80 Tapped bar 3021X0242 P306 1000589P1

81 Bumper assembly 3972X0062 P307 1000016G1

82 Bolt, hex head, 5/16-18 x 2¼" L, Gr. 8 3021X0242 P308 1000400

83 Washer, split lock, 5/16" standard 3021X0242 P309 1000323

84 Spacer bar 3021X0242 P310 1000588P1

85 Spacer, nylon, obsolete

85A Insertion resistor, 80 ohm 3021X0242P413 1002256G1

86 Six digit counter & position indicator assembly 3021X0242 P415 1000527G1

86A Counter spring for 5 digit counter 3021X0242 P321 1000146

86B Counter spring for 6 digit counter 1000147P1

86C Counter, 6 digit 1000436

86D Counter, 5 digit 3021X0242P320 1000437

86E Screws for attaching 5 digit counter 1000479

86G Counter actuator plate, 6 digit 1000509P1

86H Counter actuator plate, 5 digit 3021X0242P322 1000758P1

86J Bracket, position indicator 1000526P1

86K Faceplate, position indicator 1000193P1

86L Pointer, position indicator 1000192P1

86M Screw, round head, 4-40 x 3/8" L, zinc plated steel 1000283

86N Nut, hex, 4-40, standard, zinc plated steel 1000299

86P Washer, split lock, #4, standard, zinc plated steel 1000279

86Q Window retaining ring, 5/8" for thin wall casting 1000125P1

86R Window retaining ring, 3/4" for thick wall casting 1000125P2

86S Glass 3021X0242 P414 1000153

86T RTV sealant 1000245

9/10/2020 2:39 PM

Rev . 7



VES™ Part No.

86U Washer, internal shake proof, #10 1000608

86V Screw, round head, #10, 3/8" L, zinc plated steel 1000293

86W Washer, split lock, 1/4", zinc plated steel 1000304

86X Bolt, hex head, 1/4- 20 x 3/4", Gr. 8 1000391

86Y Nut, hex, 1/4- 20, Gr. 2, zinc plated steel 1000308

87 Insulator, 69kV 3021X0242 P402 1001152

88 Pull rod assembly, 15kV 600A module 3021B0403G1 1000402G1



90A Pull rod assembly, 69kV 600A module 1001995G1

91 Pull rod, outer, 34kV 300A three pole with Joslyn™ module 3021B0403G6 1001062G1

91A Pull rod, outer, 34kV 300A three pole with VES™ module 1001251G1

91B Pull rod, inner, 34kV 300A three pole with Joslyn™ module 3021B0403G4 1001062G2

91C Pull rod, inner, 34kV 300A three pole with VES™ module 1001251G1

92 Pull rod for 46kV 300A double module Joslyn™ design 3021B0403G7 1001988G1

92A Pull rod for 46kV 300A double module VES™ design 1001656G3

92B Pull rod for 46kV 300A single module 3021B0403G3 1000404G1

93 Pull rod for 69kV 300A double module Joslyn™ design 3021B0403G8 1000993G1

93A Pull rod for 69kV 300A double module VES™ design 1001656G4

94 Plate, closed red, 1" wide 1000540P1

94A Plate, closed red, 3/4" wide 1001400P1

95 Plate, open green, 1" wide 1000541P1

95A Plate, open green, 3/4" wide 1001401P1

96 Screw, sheet metal, #4 x 1/4" SST 10000479

97 Cable assembly, standard 15 pin, 40 ft. 1000576G3



100 Complete adjustment and repair kit 3090X0014G1 1000375

101 Shipping crate, one switch, 15 & 34kV 1000817G1

102 Shipping crate, two switch, 15 & 34kV 1000646G1

103 Shipping crate, three switch, 15 & 34kV 1000818G1

104 Shipping crate, one switch, 46kV 1000819G1

105 Shipping crate, two switch, 46kV 1000820G1

106 Shipping crate, three switch, 46kV 1000821G1

107 Nameplate 1000592P1

110 Insulator pedestal, 34kV for 34 kV three pole switch 1001978P1

111 Rear mounting bracket 1002040P2

112 Washer, flat, 0.44" OD x 0.20" ID 1002405

113 Screw, hex head, 10-32 1002450

114 Motor operator trip spring 1002664P1

115 Plastic bumper 1002670P1

116 Screw, Fillister head, 5-40 1002451

9/10/2020 2:39 PM Rev. . 7



VES™ Part No.

117 Trip solenoid 1001581

118 Semi tubular rivet 1002437

119 Spring, trip coil 1000789P1

120 Washer, flat, Delrin, 0 .5" shaft 1002428

121 Cotter Pin, (Monel), 3/4" L 1002218

122 Retaining ring, self-locking, 3/8" shaft 1002429

123 Toggle link stop shaft 1002420P1

124 Toggle link shaft 1002418P1

125 Toggle link spring shaft 1002421P1

126 Tight fit spacer, alum. 1002423P1

127 Middle linkage, motor mechanism 1002031P2

128 Bearing, needle, 5/8" thick 1000787

129 Inner bearing shaft 1002419P1

130 Washer, vinyl shim, 0.5" shaft 1002427

131 Retaining ring, e-style, 0.375" shaft 1002488

132 Spacer, large, alum. 1002424P1

133 Linkage arm 1002030P1

134 Needle bearing, 5/16" thick 1000786

135 Double linkage 1002029P1

136 Clutch arm spring pin 1002203P1

137 Motor mechanism to toggle link shaft 1002417P1

138 Trip linkage 1002032P1

139 Screw, set, 1/4-20 1002415

140 Nut, hex jam, 1/4-20 1002416

141 Side plate, non-handle side 1002182P1

142 Side plate, handle side 1002183P1

143 Bearing, one way roller clutch 1002244

144 Screw, 1/4-20 x 3/4" L 1000230

145 Washer, Belleville, 1/4" ID 1000640

146 Spring washer, motor mechanism 1002220P1

147 Spring rod end, motor mechanism 1002219P2

148 Spring, motor mechanism 1002447P1

149 Nylatron, 0 .5" shaft 1000610

150 Nut, hex jam, 3/8-16 1002226

151 Washer, Belleville, 0.386" ID x 0.813" OD 1000218

152 Screw, hex head, 3/8-16 1000480

153 Washer, split lock, #10 1000282

154 Screw, set, 10-32 x 1/2" L 1001979

155 Nut, hex, 10-32 1000302

156 Motor mechanism nameplate 1003305P1

157 Screw, hex head cap, 3/8-16 1002439

158 Washer, spring lock, 3/8" 1002474

9/10/2020 2:39 PM

Rev . 7



VES™ Part No.

160 Nylon support pin, motor mechanism 1002467P1

161 Front mounting bracket, plated 1002045P2

162 Spring pin, 3/8" dia. x 1½" L 1002289

163 Pin, nylon, 0.375" dia. x 3.5" L 1000376P1

164 Clutch arm, right-hand 1002003P1

165 Clutch arm, left-hand 1002022P1

166 Spring pin, 1/4" dia. 1002445

167 Actuator pin 1002442P1

168 Motor cam 1002007G1

169 Bellcrank clutch 1000785

170 Spring bellcrank 1000790P1

171 Cam shaft, motor mechanism 1002422P1

172 Stop lever 1002452P1

173 Mini spring, motor mechanism 1002446P1

174 Spring pin, 1/8” dia. 1000802

175 Motor, 115V, universal 1002393

176 Stud, threaded rod, 8-32 1001580P1

177 Spring pin, 3/32" dia. x 3/8" L 1000792

178 Motor side plate 1000781P2

179 Connector, quick disconnect, female 1002512

180 Washer, split lock, #8 1000281

181 Nut, hex, 8-32 1000301

182 Worm, modified 1001584P1

183 Mini cam shaft 1001583P1

184 Mini nylon cam 1001582P1

185 Worm gear, modified 1001585P1

186 Motor front plate 1002663P1

187 Spring pin, 3/32" dia. x 5/8" L. 1000793

188 Washer, felt, 1/4" ID x 1.5" OD 1002999

189 Washer, steel, 1/4" ID x 7/8" OD 1003000

190 Worm gear spring, 1/4" shaft, 11/16 1003001

191 Washer, Nylatron, 0.25” shaft 1000096

192 Vibra-Tite Formula 3™ thread locker 1000074

193 Loctite 272, red 1002682

194 Motor oil 10W30 1000754

195 Moly fortified grease 1000755

196 Standard motor assembly 1002399G1

197 Motor mechanism assembly 1002673G1

198 Cable harness, 15 connector assembly 1002817G1

199 Cable harness, 35 connector assembly 1002801G1

200 VES-M contact block assembly, handle side 1003241G1

201 VES-M contact block assembly, non-handle side 1003241G2

9/10/2020 2:39 PM Rev. . 7



VES™ Part No.

202 Contact block mounting kit, 15 Pin 1003360G1

203 Contact block mounting kit, 35 Pin 1003360G2

204 Relay panel assembly, 120/48V 1002823G1

205 Relay panel assembly, 125V 1002823G2

206 Transfer bar, contact block, 35 Pin 1003261P1

207 Spring, motor operator 1000788P1

208 Spring pin, 1/8” dia. x 1½” L 1002289P1

9/10/2020 2:39 PM

Rev . 7


Failure Diagnostic Charts

Capacitor Banks In General

Failure Mode Possible Causes Possible Corrective Actions

Blown capacitor fuse or capacitor can rup-ture with repeated occurrences

Switch restrike following switching caused by leaking vacuum interrupter, excessive in-rush current on closing, or parasitic capacitance reducing recovery withstand voltage of switch. For switches with mechanically separate mech-anisms, the contacts in all three phases may not be closing or opening at the same time.

Even if vacuum interrupters pass hi-pot test replace them with vacuum interrupters with known leak tightness. Install reactors to limit in-rush current because high inrush currents can increase restrike probability. Remove physical objects close to the vacuum interrupter modules or install vacuum inter-rupters with grading capacitors. Install a stored energy control to assure that all switches close at the same time.

Module failure with the switch in the open position

Loss of vacuum in the vacuum interrupter. Hi-pot test and replace failed vacuum interrupter modules.

Module overheating and failure with the switch in the closed position.

Vacuum interrupter contacts are barely touch-ing resulting in high contact resistance and the generation of too much heat. This can be caused by either the switch being out of adjust-ment or for a solenoid operated switch, having inadequate power to close completely.

Check and readjust switches. Having inadequate power to operate the switch is very common when switches are operated from an AC or DC line. The available current is checked with a digital oscillo-scope and a current probe. For a solenoid operated switch, the solenoid should complete its stroke in 1½ cycles. Solenoids taking longer may operate the switch but over a long period of time they many not be reliable. Correct by increasing the available cur-rent. Boost boxes or a stored energy control can solve this problem.

Radio noise in the vicinity of an open vacuum switch.

The radio noise is caused by electrical dis-charges in the vacuum interrupter as a result of losing vacuum.

Hi-pot test and replace failing vacuum interrupters.

Arc Furnaces In General

Failure Mode Possible Cause Corrective Actions

Exploding phase-to-ground arrestor

An exploding phase-to-ground arrestor is caused by applying single or two phase power to a transformer which has transient suppres-sion capacitors connected to the transformer bushings resulting in ferroresonance.

-OR- When the furnace switches are connected to the transformer by long cables, applying power to only one or two phases can cause an over voltages by ferroresonance.

The solution to this problem is to install a new control which will prevent single or two phase power from being applied to the transformer.

9/10/2020 2:39 PM Rev. . 7


Vacuum Switch Failures in General

Failure Mode Possible Causes Corrective Action

Hi-pot failure of vacuum interrupter

Air leak into the vacuum interrupter. Replace Joslyn™ module with a Module having a Mitsubishi™ vacuum interrupter. VES modules are warranted to 60,000 oper-ations and have a recommended useable life of 250,000 operations.

High resistance failure of Joslyn™ vacuum in-terrupter

Relaxation of mechanical electrical connec-tions inside the module.

VES modules are built with Belleville spring washers on all mechanical electrical connections to keep resistance low by main-taining the bolt tension.

Welding together of vacuum interrupter con-tact buttons

Excessive wear resulting in improper over travel setting on vacuum interrupter module so as to cause excessive contact resistance or contacts barely touching on closing.

Disassemble switch and replace bearings every 100.000 switch operations. Replace Joslyn™ pull rods, and pull rod screws with VES equivalent replacement parts. Prevent pull rod slippage by using grade 8 fasteners, flat washer, lock washers, and thread locker to clamp pull rod clevis securely. The VES parts reduce wear by replacing aluminum material with stainless steel.

Occasional out of se-quencing tripping of solenoid operated switches

For three phase sets of capacitor switches, out of sequence trips will occur when all switches do not open or close within a certain time win-dow. This may be caused by the switches be-ing out of adjustment but also may be caused by an inadequate amount of current being available to operate the switches.

Wear in the bumper assemblies can cause a switch to operate slowly and result in out of sequence trips. Replace bumper assemblies with VES bumpers having more durable urethane bumpers.

An inadequate availability of solenoid oper-ating current will intermittently cause out-of-sequence trips. Too small wires and long wire run lengths to the power source will cause this problem.

Arc Furnaces in General (continued)

Failure Mode Possible Cause Corrective Actions

Counts on the phase-to-

ground arrestor discharge counters

Counts on the phase–to-ground arrestors are

caused by ferroresonance resulting from brief periods of loss of power to one or two phases on a transformer with transient suppression

capacitors connected to the transformer bush-ings.

The solution to this problem is to install a new

control which will prevent single to two phase power from being applied to the transformer.

Counts on phase–to-phase

arrestors.

On a transformer with transient suppression

capacitors a transient discharge is occurring through a power factor correction capacitor bank in the local substation.

Install a damping resistor in series with the

transient suppression capacitor to make the capacitor discharge overdamped.

Catastrophic module ex-plosion in two phases with

no prior indication of module failure

Exceeding switch’s 4000 ampere interrupting rating as a result of having over current relays or emergency stop button connected to the Joslyn ™ switches.

-OR- Failure to detect vacuum loss failure in one

phase before a vacuum loss occurred in a sec-ond phase.

Connect over current relays & emergency

button to back up breaker. Alternately, on small furnaces install a control with a Schweitzer over current relay to prevent open-

ing the switch at excessive current.

-OR- Hi-pot test vacuum interrupters every three

months.

9/10/2020 2:39 PM

Rev . 7


Solenoid Operated Switches in General

Failure Mode Possible Causes Corrective Actions Blowing fuses in the control

Link angle adjustment is out of spec due to bumper assembly wear.

-OR-

Supply transformer is too small.

Replace Joslyn™ bumper assemblies with VES bumper assemblies made with more wear resistant urethane bumpers.

-OR-

A 5kVA 3.5% max impedance transformer is required for each 3 phase set of switches. The transformer must be installed next to the control.

Fracture in pull rod clev-is

A cyclic fatigue failure at the clevis corners. Replace pull rod with VES pull rod having structural support to prevent flexing at clev-is corners.

Thread pull out in pull rod plug

The aluminum material has poor wear charac-teristics.

Replace pull rod with VES pull rod having stainless threaded plugs.

Control yoke fracture at point of yoke bumper stop contact

Cyclic fatigue due to yoke bumper stop impact on control yoke.

Replace Joslyn™ yoke bumper stops with VES all rubber bumper stops.

Control yoke fracture next to nylon pin contact pad

Cyclic fatigue fracture due to nylon pin im-pact.

In the field, replace control yoke every 100,000 operations. In the shop, change handle shaft from 1/2” to 3/4” dia.

DECCO™ solenoid coil failure

Shorted turns in coil. Replace coils with vacuum impregnated coils.

Mushrooming of nylon pin ends

Control malfunctioning due to excessive volt-age drop in electrical supply to control or ex-cessively high voltage being supplied to the control.

Correct the supply voltage to the control or increase kVA rating of supply transformer and wire size from transformer to control.

Fractured and bent nylon pins

Wear in the solenoid has decreased the air gap so that the solenoid sticks due to residual mag-netism.

Replace solenoid with new solenoid assem-bly having a 0.030” air gap.

Spring assembly or spring retaining clevis pin failure

Lack of lubrication. Install felt lubricating washers and lubri-cate.

Toggle link bearing jour-nal wear

No lubrication on bearing journal. Replace toggle link with link having an oil impregnated sintered bronze bearing.

DECCO™ fractured solenoid side plate

Cyclic fatigue of side plate. Replace side plates with stress relieved side plates. Prevent side plates from flexing by installing spacer kit.

DECCO™ sticking sole-noid armatures

Loss of air gap resulting in residual mag-netism causing sticking.

Replace armature with new armature having a 0.030” air gap.

Namco™ solenoid bind-ing of armature

Galling of stainless solenoid armature bearing plates.

Replace stainless steel bearing plates with bronze bearing plates.

9/10/2020 2:39 PM Rev. . 7


Solenoid Operated Switch Failures in General (continued)

Failure Mode Possible Cause Corrective Action

Solenoid mounting bolts vibrating loose

Failure to maintain bolt tension in mounting bolts.

Install screw-lock helicals in aluminum mech-anism casting.

Auxiliary switch failure

Eaton™ Aux switch failure. Replace Eaton™ switch every 250,000 opera-tions.

Square D™ aux switch fracture

Wear in bumper assembly caused the switch adjustment to change resulting in impact forc-es on the plastic housing.

Replace bumper assembly with VES bumper assembly having a urethane rubber bumper. Replace Square D™ switch with Eaton™ switch.

Spring pin failure in handle or control yoke

Excessive impact forces on spring pins. Replace Joslyn™ handle with VES low inertia handle. Install control yoke with 3/4 in shaft for handle.

Switches trip open immediately on clos-ing

The emergency trip capacitors are tripping the switches open because one switch is slower than the others.

This problem can be diagnosed by disconnect-ing the emergency trip capacitors to prevent the emergency trip on closing. Close the switches electrically and observe which switch is not properly closing then install new bump-ers assemblies and readjust link angle, full travel, and overtravel.

Motor Operated Switch Failures in General


Motor runs but switch does not close

Fiber worm wheel gear or bearing journals at the end of worm wheel shaft are worn out.

Replace motor assembly with a new motor assem-bly having a brass worm wheel and bronze jour-nals for the worm wheel shaft that are lubricated with felt lubricating washers.

Motor operated switch takes too long to charge springs

Ratcheting cams are slipping in alu-minum boomerang journals. The ratcheting cams are mounted in too soft aluminum boomerang material.

Replace the aluminum boomerangs with boomer-angs made from stainless steel. Alternatively, replace the entire motor assembly.

Motor operator switch trips immediately on closing

The link angle is too large. Readjust the closing bumper to reduce the link angle to 1 degree in the direction of opening.

Motor operator switch trips immediately on closing

The trip mechanism is out of adjust-ment possibly because the trip link is worn because it is made from soft aluminum.

Replace trip link with a trip link made from steel and readjust switch.

Spring bolt fractured Bending stress in the bolt is concen-trated at the locking nuts.

Replace bolt assembly with a new bolt assembly having an eye bolt to attach the spring to the switch mechanism. These parts remove the stress concentration.

Motor armature fails in ap-proximately 100 operations

The wrong voltage is applied or the wrong relay panel is installed, or the wrong jumpers are installed.

Determine the voltage to be applied and then se-lect the correct relay panel and jumpers.

9/10/2020 2:39 PM

Rev . 7


Motor Operated Switch Failures in General (continued)


Spring tab on motor opera-tor side plate fractured

Cyclic fatigue failure of fillet weld. Replace both side plates with new side plates having brazed (rather than fillet) welded tabs.

Motor does not want to start after a long period of being idle

Corrosion on its armature bars inter-feres with the flow of current though the armature.

Spray contact cleaner on armature bars to get motor start-ed. Install adhesive mounted heater on motor to prevent corrosion on armature bars.

Square D™ auxiliary switches crack and fail

Caused by excessive wear in the bumper assembly.

Replace both bumper assemblies with bumpers having more wear resistant urethane bumper. Replace Square D ™ auxiliary switches. Alternatively, replace Square D™ auxiliary switches with the Allen Bradley™ auxiliary switch.

9/10/2020 2:39 PM Rev. . 7


Recommended Maintenance for

Vacuum Electric Switch Company Products

CAUTION: HAZARDOUS ENERGY

Vacuum Electric Switch Co. products are high voltage equipment with the potential to kill or injure individuals not following appropriate proce-dures. Personnel must be trained according to an established standard such as NFPA 70E, Standard for Electrical Safety in the Workplace, availa-ble from www.nfpa.org or: National Fire Prevention Association 1 Battery March Park, P.O. Box 9101 Quincy, MA 02269-9101 USA This standard establishes appropriate safety training and procedures for servicing this equipment. All equipment must be de-energized, locked out, grounded, and proven to be de-energized prior to performing maintenance. Switches have two sources of energy. One is from the high voltage source, and the other is from control power through the control cable. Completely de-energizing a switch requires removing both. Switches also contain stored energy in springs, and caution must be exercised to prevent unexpected operation of the switch mechanism. Hi-pot testing required by this maintenance procedure involves danger-ous high voltages. Safe hi-pot testing requires a cleared area between the equipment under test and personnel as specified by NPFA 70E, Standard for Electrical Safety in the Workplace. Controls require locking out their electric power source and removing the stored energy in their capacitors prior to servicing. Testing an energized control or switch should be done in accordance with NFPA 70E, Standard for Electrical Safety in the Work-place.

9/10/2020 2:39 PM

Rev . 7


Switches and Modules

The appropriate maintenance schedule depends on frequency of switch operation and the economic

impact of unplanned down time. Switches and modules as mechanical equipment are subject to slow

rates of degradation and wear. The purpose of regularly scheduled maintenance is to identify and cor-

rect problems before they cause unexpected down time resulting in significant economic loss. Needed

repairs should be identified so they can be done as part of conveniently scheduled maintenance rather

than allowing a failure to cause an unexpected and sudden shut down of operations. Switches that oper-

ate frequently and where the economic impact of failure is substantial, need to be inspected and tested

more often in order to avoid the consequences of an unexpected failure. This recommended mainte-

nance is preventative in nature.

Scheduled Maintenance for Applications where the Operation of the Switch is Either Frequent or

the Economic Consequences of Switch Failure are Substantial

This category of application includes the operation of industrial equipment where the suspension of

operations results in large economic losses that are impossible to make up because of loss of productive

time. Frequent operation is once every hour or more with annual number of operations exceeding

10,000. An example is the operation of electric arc furnaces where operations are expected to continue

twenty-four hours a day seven days a week with only occasional shut-downs for planned maintenance.

For this category of application recommended maintenance is:

1. At Installation

A. Log date of installation

B. Log switch counter reading

C. Hi-pot switch modules at 30kVAC RMS - leakage current should be less

than 2mA – log results by module and switch serial numbers

D. Measure module terminal-to-terminal resistance – should be less than 100

micro-ohms at installation, reject at greater than 200 micro-ohms – log re-

sults by module and switch serial numbers

2. Quarterly

A. Hi-pot modules and log results by module and switch serial numbers

B. Measure module resistance and log results by module and switch serial

numbers

C. Log counter reading and date of time of service

3. Annually

A. Hi-pot modules and log results by module and switch serial numbers

B. Measure module resistance and log results by module and switch serial

numbers

9/10/2020 2:39 PM Rev. . 7


C. Measure timing and synchronization of modules either by a dynamic test of

switch operation or a static test from opening the switch and taking physical

measurements. Readjust switch mechanism to specifications as necessary

D. Log counter reading and date at time of service

4. At every 100,000 operations

A. Replace all ¼” shaft diameter bronze bushings in switch

B. Replace control yoke and associated bushings, spring pins, and cotter keys

C. Replace spring assemblies and associated spring retaining clevis pins and

felt lubricating washers. Lubricate the felt washers

D. Replace bumper assemblies

E. Replace yoke bumper stops

F. Readjust link angle, full travel, and synchronism between modules

G. Replace nylon pins and adjust gap

H. Readjust Eaton auxiliary switch

I. Log counter reading and date at time of service


A. Replace Eaton auxiliary switch and wiring harness assembly

B. Replace module assemblies

C. Log counter reading and date at time of service


A. Replace or overhaul the solenoid assembly depending on the type of sole-

noid installed. DECCO solenoid assemblies should be replaced. NAMCO

solenoid assemblies can be disassembled and worn parts and damaged coils

replaced

B. Log counter reading and date at time of service

Scheduled Maintenance for Applications where the Operation of the Switch is Occasional or the

Economic Losses due to Switch Failure can be Contained to Reasonable Levels

In this category of application, the failure of a switch is basically an inconvenience characterized by

reduced efficiency, increased cost, or a reduction in capacity but would not bring operations to a halt.

The repair of failed equipment would not require immediate action. Economic losses are containable to

reasonable levels. Occasional operation is one or two times a day and sometimes only seasonal usage.

The number of annual operations is frequently less than 1,000 or but could be as much as 10,000.

1. At Installation

A. Log date of installation

B. Log switch counter reading at installation

9/10/2020 2:39 PM

Rev . 7


C. Hi-pot switch modules at 30kVAC RMS – Leakage current should be less than

2mA - log results by module and switch serial numbers

D. Measure module terminal-to-terminal resistance - should be less than 100 micro

-ohms at installation. Reject at greater than 200 micro-ohms. Log results by

module and switch serial numbers

2. Annually

A. Hi-pot modules at 30kVAC RMS and log results by module

B. Measure module terminal-to-terminal resistance – should be less than 200 micro

-ohms. Log results by module and switch serial numbers

C. Log switch counter and date at time of testing

3. Every Other Year

A. Open switch, measure and readjust (if necessary) link angle, full travel, module

synchronization, pin gap, and auxiliary switch actuation settings

B. Log counter reading and date at time of service

Parts

The recommended maintenance schedule for parts is the same as for the switch in which they are in-

stalled.

Controls

Controls do not require following a regular preventive maintenance schedule.

9/10/2020 2:39 PM Rev. . 7


1. Analyzing Vacuum Interrupter Module Failures

Vacuum Interrupter modules can fail for many reasons other than the vacuum interrupter itself failing. Finding the cause of a failure starts with gathering physical evidence. The physical evidence of failure can be classified in three different types. The first type is a vacuum interrupter failure with no external visible evidence of failure. The second type is a failure with evidence of overheating but no explosive force. The third type is a failure ac-companied by explosive hot gases.

1.1 Module Failures with the Failure Not Visible When a module fails without visible evidence, hi-pot or resistance test equipment must be used to detect the oc-currence of the failure. Failed vacuum interrupters sometimes emit radio frequency noise which can be picked up by an ordinary AM radio in the vicinity of the vacuum switch.

1.1.1 Hi-Pot Test Failure A failed vacuum interrupter can be identified by applying a 30kVAC voltage to the potted vacuum interrupter contacts. The vacuum interrupter under test should have leakage current of less than 2mA. Vacuum interrupter modules that have excessively contaminated surfaces should be cleaned to avoid a false test result from leakage current flowing over the external surface of the module.

The Vacuum Electric Switch Co. uses Mitsubishi™ vacu-um interrupters to build its vacuum interrupter modules. This vacuum interrupter is a load break switch and not a fault inter-rupter. If used to interrupt a fault current exceeding 4000 am-peres, it will fail catastrophically even on the first operation.

Mitsubishi’s™ vacuum interrupter intrinsic failure rate is

less than three failures per 100,000 vacuum interrupters per 100,000 hours of operation.

Mitsubishi™ Vacuum Interrupter

1.1.2 High Resistance Failure Vacuum interrupter modules should have a terminal-to-terminal resistance of less than 200 micro-ohms when measured with a Kelvin-lead micro-ohm meter. The cause of the high resistance can be external or internal to the vacuum interrupter. When the high resistance is external, it is caused by loss of bolt tension in the bolted me-chanical connections in the current path through the module. Many modules with too high a resistance can be repaired by tightening its bolts. The Vacuum Electric Switch Co. prevents mechanical connections from developing high resistance by using high strength fasteners such as grade 8 or stainless steel bolts. The grade 8 bolts are used inside the modules and the stainless steel bolts are used on the outside where corrosion resistance is important. Belleville washers are used with the fasteners to maintain tension in the fastener and compressive forces on the electrical joint.

9/10/2020 2:39 PM

Rev . 7


1.2.1 Partial Loss of Vacuum Loss of vacuum normally is detected with a hi-pot test at 30kVAC which is more than twice the normal voltage applied to a vacuum interrupter. At this voltage the vacuum interrupter is rejected if the current exceeds 2mA. If the loss of vacuum is sufficient that 100mA of current can flow at the normal voltage applied to a vacuum in-terrupter, 15kW of heat will be generated. This is a large amount of heat that will cause abundant smoke and decomposed potting material.

1.2.2 Excessive Voltage Applied to the Vacuum Interrupter A phenomenon called ferroresonance exists which can generate voltages many times the normal system voltages applied to a switch. Ferroresonance accidentally occurs as a result of an abnormal circuit formed by a combina-tion of capacitors with the inductance of transformer windings. A large leakage current flows though as an open vacuum interrupter. Ferroresonance failures occur slowly as a large amount of heat accumulates causing a tarry and smokey mess.

1.2 Module Failure with Only Overheating Evidence When a vacuum interrupter overheats but no explosive blast has occurred, the overheating is a result of exces-sive leakage currents between the vacuum interrupter contacts. In this situation the module potting material will be decomposed into a sticky, tarry mess with abundant smoke. The decomposed potting material may be found everywhere, coating both inside the switch and outside the module. This type of failure can have several causes including partial loss of vacuum, excessive voltage applied to the switch, and contacts almost (but not actually) touching. When analyzing an overheating failure, the position of the linkages inside the switch can be important evidence of how the failure occurred. The smoke and tarry mess coats the internal parts of the switch and can cast shadow images of parts on adjacent material. The contact surfaces of bumpers can shield material from being coated with the mess. These images will indicate the position of the switch mechanism when it failed and can assist in forming conclusions in how the failure occurred.

Preventing Increases in Resistance

9/10/2020 2:39 PM Rev. . 7


1.3.1 Loss of Vacuum A vacuum interrupter can fail explosively due to loss of vacuum if the loss of vacuum is sufficiently complete. A vacuum interrupter with a very large leakage current at normal load voltages would not be able to interrupt a normal load current and would fail catastrophically.

1.3 Module Failure with Explosive Force When explosive gases are emitted from a vacuum interrupter module, the cause is a failure to interrupt a current. The explosive gases are externally evidenced by the rupture of a breather bag or ejection of the bladder cover and blow out of panels. There are two causes of this type of failure which are both a result of failure to inter-rupt. When a vacuum interrupter parts during normal operation, an arc forms between the contact buttons. When the AC current passes through zero, the arc is extinguished. If the contact buttons become hot, the arc is reestab-lished then the vacuum interrupter fails to interrupt. During this type of failure, the arc ruptures the vacuum en-velope at the bellows. The arc plasma flows down through the inside of the line-to-ground insulator and flashes over to the switch mechanism. Mechanism parts are melted. Which parts and which edges of the mechanism are melted indicate the position of the switch at failure. This can be used to explain how the failure occurred. The failure is arrested by an up-stream breaker. This type of failure is distinguished from a failure with only overheating in that all the arc blast products are dry and no sticky tar is found anywhere. This is because the arc temperature is so high as to completely decompose any organic material.

1.2.3 Failure to Close Completely Sometimes switches with multiple vacuum interrupters will fail to close completely because insufficient force was exerted on the switch contacts during switch closing. This is most likely to occur on a solenoid operated switch when insufficient electrical power is available to operate the switch. During normal operation of a switch, the switch mechanism brings the contacts together and then compresses an overtravel spring in each module. The spring is compressed about 0.040 inch at each end of the vacuum inter-rupter to assure that each has the proper amount of force on its contacts. If an adequate amount of current is not available to close the switch, the overtravel springs may not be fully compressed. The contacts of one or more vacuum interrupters may only barely touch or not even touch at all. When the current flows through the barely touching contacts a large amount of heat will be generated. The pot-ting material will be decomposed into black sticky, tarry mess with abundant smoke.

Ferroresonance Failure

9/10/2020 2:39 PM

Rev . 7


1.3.2 Failure to Interrupt The 600A vacuum interrupters inside the modules have a 4000A RMS interrupting rating. The vacuum inter-rupter can conduct a current much higher than 4000A RMS, but it cannot interrupt the current. If an attempt is made to interrupt a current higher than the interrupting rating, the vacuum envelope at the bellows end will be breached. Arc plasma will flow down the inside of the line-to-ground insulator and flash over to ground. An up-stream breaker will interrupt the current. Failures to interrupt most often occur when the vacuum switch is improperly connected to an over-current relay. Vacuum switches are load break switches. They should not be used for fault interrupting except in very limited cases. If the fault current can be assured to be within the switch interrupting rating, the vacuum switch can be used for fault interrupting. This is sometimes possible with very small arc furnaces. Sometimes a back-up breaker and a vacuum switch are both improperly connected to the same overcurrent relay. The vacuum switch is mechanically so much faster than the breaker that it attempts to interrupt the current first but fails. The back-up breaker then opens and interrupts the current. Such an arrangement can be identified if a switch first fails to interrupt, but the destructive process is arrested before the arc blast plasma can flash over to ground.

9/10/2020 2:39 PM Rev. . 7


2. Switch Mechanical Failures

Switch electrical failures associated with the vacuum interrupters and their analysis and prevention are dis-cussed in paragraph one under the heading “Analyzing Vacuum Interrupter Module Failures.” General me-chanical type failures are discussed in this section. Some switches are powered by solenoids, and the associat-ed failures are discussed starting at paragraph 2.3, Solenoid Operated Switches. Other switches are powered by motors and their failures are discussed starting at paragraph 2.5, Motor Operated Switches.

2.1 Cotter Pin Failures The VBM and VBT switches have many parts held together with cotter pins. The cotter pin material is im-portant in preventing cotter pin failure. Stainless steel cotter pins should not be used in these switches. Stain-less steel cotter pins are subject to stress corrosion due to chlorides in the environment. Bending the cotter pin concentrates stress at the bend, which will then be followed by breakage of the cotter pin and the switch mecha-nism coming apart. All of the cotter pins used in assembling VBM and VBT switches are made of Monel, which is not subject to such failures.

2.2 Module Failures

There are three types of modules associated with these switches. The first is the 600A module. For the past sixty years this module has been made with acrylic, ceramic, and epoxy housings. It is currently being made with aliphatic epoxy housings. The second type of module is a fabricated module with rubber sheds. It is built in 300A and 600A versions and one module is usually stacked on top of another making what is called a double stacked module. This module is made from a fiberglass tube with rubber sheds and aluminum flanges. The third type of module is a resistor module containing an 80 ohm power resistor.

2.2.1 Excessive Heat When a resistor module fails due to excessive heat, the cause is a control failure. The resistor modules are used for transient in-rush current control. They are inserted in the circuit for only 100 milliseconds when the equip-ment is first energized and then bypassed by a second switch. If the resistor module stays in the circuit too long it overheats. The cause is the control’s failure to switch in the bypass switch.

2.2.1.2 Too High Resistance Sometimes the resistance of the resistor module increases so much that sufficient current cannot flow through the module. There are two possible causes. The first is moisture absorption by the resistor element inside the module. This is unlikely to occur if the resistor is being regularly energized because the heat from energization will evaporate any moisture. The moisture can be removed by heating the resistor elements at 250°F.

The second cause of increases in resistance is corrosion. The resistor elements have metalized contact surfaces for making connections between elements. These elements are an old product and as originally produced, the metalized surface was a brass material. The brass material is subject to atmospheric corrosion which then in-creases the resistance. More recently, aluminum has been used for the metalized surface because the aluminum is not subject to corrosion. Resistor modules manufactured by the Vacuum Electric Switch Co. after 6/7/2020 have aluminum contact surfaces.

Old Design: Brass Contact

9/10/2020 2:39 PM

Rev . 7


2.2.2.1 Fractured Flanges Fracture of the 600A module flanges from over tightening of the mounting bolts is a common problem. The mounting bolt torque limit is only 25 inch-pounds. This is only a small torque which could easily be exceeded if a torque wrench was not used when installing the module. The Vacuum Electric Switch 600A module housing has been redesigned to include a stress reducing radius where the flange is attached to the module housing. The flange is contoured around the mounting bolt holes. This change in module design makes it difficult to accidentally crack a module housing during installation.

2.2.2 Resistor Modules Resistor modules look similar but are different from vacuum interrupter modules. They can be identified by the rod establishing an arc gap from one terminal to another. They are sometimes stacked on top of other switch modules using special parts. The resistor module has a terminal-to-terminal resistance of 80 ohms and contains eight 10 ohm, 10kV rated resistor elements. One 80 ohm resistor module per phase is required to build a resistor insertion switch at 15kV and two at 34kV. Each resistor module has an arc gap is to prevent an internal flash over inside the module housing from occur-ring if too much current flowed through module. The arc gap is established by a metal rod on the outside of the module. Resistor modules fail either due to excessive heat or too much resistance.

9/10/2020 2:39 PM Rev. . 7


2.2.3.1 Flange Bonding Failure Sometimes flanges may become unbonded from the fiberglass tube. The Vacuum Electric Switch Co. has insti-tuted proof testing of the housings to test the adhesive bonded flange. After the housing fabrication is complet-ed, the housing is put in a press and a 2000 pound axial proof load is applied to the housing. This load is testing the housing to the limits of its strength. A higher load would cause bending of its flanges. At the same time the proof test is being conducted, 20 PSIG of pressure is applied to inside of the module to as-sure that the adhesive bond is leak tight. This leak test is as compared to a 1½ PSIG leak test which is later ap-plied to a finished switch.

2000 Pound Proof Test and 20 PSIG Leak Test

2.2.3 Double-Stack Modules The double-stack module housings are fabricated from filament wound resin bonded tubing. Sheds are pressed over the outside and flanges are adhesive bonded to the ends.

2.2.3.2 Shed Deterioration Shed deterioration is greatly improved by making the sheds of silicone, rather than EDPM rubber.

2.2.3.3 Pull-Rod Slippage Double stack modules have internal pull rods that connect the vacuum interrupter in the upper module with the vacuum interrupter in the lower module. Maintaining the synchronism of the upper vacuum interrupter with the lower vacuum interrupter depends on securely fastening the internal pull rods to the drawbars. The pull rods are fastened to the draw bars with a compression type steel fitting having a ferrule with internal teeth. The fitting is tightened with an impact wrench.

Drawbar Nut

Drawbar

Ferrule

Pull Rod

Pull Rod/Draw Bar Connection

9/10/2020 2:39 PM

Rev . 7


Upper Module of Double Stack Module

2.3 Solenoid Operated Switches When more than one switch mechanism is used in a set, the switches are always solenoid operated. Solenoid operated switches have either two or four solenoids supplying the energy to open or close the switch. A switch with two solenoids has one solenoid for opening and a second solenoid for closing the switch. A switch with four solenoids has two solenoids mechanically connected in parallel for both opening and closing the switch. The four solenoid switch is commonly called a double solenoid switch. Solenoid operated switches always re-quire special controls. The number of solenoids determines how much energy is available to operate the switch. A switch with one opening and one closing solenoid can operate a switch with up to four vacuum interrupters. A switch with two opening and two closing solenoids is required for six vacuum interrupters. Solenoid operated switches close and open in a predictable and controlled amount of time. This makes it possi-ble to have multiple switches which are not mechanically connected to each other all operate at the same time. Switches can be connected in parallel to increase the current capacity beyond the capacity of a single switch. Solenoid operated switches have reproducible operating times which makes possible the closing of switches in synchronism with the power frequency sine wave to reduce transients.

2.3.1 Power Source Induced Failures A solenoid operated switch can either have a stored energy control or a line-powered control. In a stored energy control, the adequacy of the available power is assured by having it stored in capacitors in the control. The only cause of inadequate power in a stored energy control is that the capacitors may lose capacitance over a period of time of ten years or more and need replacement. In a line-powered control, the power comes from an external transformer or batteries. The conductors bringing power to the control must be adequately sized for the number of switches. Too long a distance between the switch and the power sources may reduce the amount of available current to unacceptably low levels. An indi-vidual switch needs 60 to 65 amperes peak current for it to operate properly. If the current is not available, the switch will operate slowly. If a switch has two solenoids for opening and closing, it will need twice as much current. The trip solenoid requires more current than the closing solenoid, and for this reason problems with in-adequate current always are first apparent on switch opening. Having adequate available power is an essential element of a properly operating switch installation.

9/10/2020 2:39 PM Rev. . 7


2.3.1.1.1 Furnace Switches

Sizing a power source for an installation of furnace switches is straight forward. A control must have 5kVA, 3½% maximum impedance of transformer capacity for each three-phase set of switches connected to the con-trol. A 3½% impedance transformer is a special order transformer, and where it is not available, a 10kVA 7% max impedance transformer can be substituted. The transformer must be connected to a higher voltage such as 220 or 480VAC and be physically located next to the arc furnace control. It must be directly connected to the control with sizeable wire considering that each three-phase set of switches draws 190A peak for a cycle and a half. The transformer should not be shared with other equipment operating simultaneously. A furnace control supplied with power as described above will oper-ate properly.

2.3.1.1 Blown Fuses Repeated blown fuses in a Joslyn™ control is symptomatic of an inadequate amount of available current to op-erate a solenoid operated VBM or VBT switch. The fuse for each three-phase set of switches should be a 10A type FNM dual-element slow blow fuse. This type of fuse is designed to accommodate the in-rush current dur-ing the proper operation of the switch solenoids. If the switch takes too long to operate the fuse will blow, which indicates inadequate supply of electric current. Substituting a larger fuse to prevent fuse blowing will result in damage to the pins in the connector on the side of the switch.

2.3.1.1.2 Substation Switches

Supplying line-powered switches in a substation is more problematic. This is because they can be supplied by batteries or station transformers. Station transformers will generally have more than enough KVA capacity to operate the switches. The big problem with substation installations is the linear distance of wire run length be-tween the station transformer or the batteries. The current that can be supplied is limited by both the wire run’s resistance and inductance. The inductance will be affected by whether the wire is in a metallic or non-metallic conduit. The 34kV three pole solenoid operated switch is particularly sensitive to being supplied by an inadequate cur-rent supply. Because this switch internally has two open and two closing solenoids, it requires 120 to 130 am-peres peak to operate, which is twice as much as the other switches having only one solenoid. The current is being supplied over the same pendant cable with #16 AWG wire, resulting in a much larger voltage drop in the cable. There is no easy way to calculate the size of wire required to deliver the required current. Rules of thumb, such as installing two #6 AWG wires in parallel, may enable a switch to operate but not necessarily under all condi-tions. The adequacy of an installation needs to be verified with a current measurement using a current probe with a digital oscilloscope. In an adequately sized installation the current operating the solenoid will flow for 24 milliseconds maximum. The switch may function with longer times but insufficient margin exists to assure the switch operates properly every time. Given the many problems of assuring an adequate amount of current is available in a substation installation, us-ing stored energy controls for solenoid operated switches in substations is recommended.

2.4 Catastrophic Switch Failures Catastrophic Switch failures are those which cause the switch to quit operating immediately. These types of failures are normally the result of a large accumulation of operations. A catastrophic failure is distinguished from a failure due to wear, which proceeds slowly and progressively.

9/10/2020 2:39 PM

Rev . 7


2.4.1 Solenoid Failures Solenoids used on the switches were first manufactured by NAMCO and now by DECCO. The NAMCO sole-noids were larger and more rugged than the DECCO solenoids. For this reason solenoid failures normally occur with DECCO and not NAMCO solenoids. The types of solenoid failures consist of a failed coil, sticking solenoid armatures, fractured parts, and the sole-noid vibrating loose. These types of failures are usually found in switches with annual operating rates of more than 10,000 operations per year. Normally such usage is found in steel mills where switches are used to turn arc furnaces on and off. Of the two solenoids on the switch, the trip solenoid is most likely to fail. More power is required to open the switch, and as a result, it is subjected to more wear than the closing solenoid. Solenoid failures can be precipitated by an inadequate amount of available current to operate the switch. If the current is inadequate, the switch will operate slowly. A slowly operating switch will initiate the opening of the switch using the under-voltage trip circuitry which is powered by charged capacitors. The energy available is larger than normal, and repeated use of the under-voltage trip circuitry may cause a solenoid failure.

2.4.1.1 Shorted Coil Turns When a solenoid is operated, all the force exerted by the solenoid is also applied to the turns in the solenoid coil. The force on the turns can cause the wires to rub on each other which wears off the insulation. The turns may become shorted, and shorted turns cause the solenoid to lose the power to operate the switch. DECCO solenoid coils may or may not be vacuum impregnated as indicated by the color of their leads. Coils with white leads are impregnated. Impregnated coils have all the voids between the wires filled with solidified resin which prevents the wires from rubbing on each other and becoming shorted. Replacing coils with yellow lead wires is part of the Vacuum Electric Switch Co. normal switch overhaul pro-cess.

9/10/2020 2:39 PM Rev. . 7


2.4.1.2 Loss of Solenoid Air Gap Solenoids have an air gap intentionally designed into the magnetic circuit inside the solenoid. The purpose of the air gap is to prevent residual magnetism in the solenoid’s iron from holding the armature in the closed posi-tion after the electric power is turned off. Loss of the air gap is observed as the armature sticking in the ener-gized position. It is also observed as bent and deformed nylon pins. During the operation of the solenoid, the repeated impact of the armature on the field stack deforms the pole fac-es, thus reducing the air gap. DECCO solenoids as originally designed by DECCO have a 0.009 inch air gap. Solenoids supplied by the Vacuum Electric Switch Co. have their air gaps increased to 0.030 inches, which is large enough to maintain a proper air gap for more than 1,000,000 switch operations. If the armature sticks in the energized position due to a loss of the air gap, the nylon pin fails to fall back down when the power is turned off. On the next operation the control yoke is flipped over hitting and bending the ny-lon pin. The shock of the impact knocks the armature loose which then returns to its proper position. With the armature now in its proper position, evidence of the cause of the failure is lost. This type of failure is difficult to diagnose because the only surviving evidence of the cause of failure is the bent nylon pin. Replacing the nylon pin will not prevent further failures.

2.4.1.3 Fractured Parts DECCO solenoid side plates may fracture in fatigue due to repeated operation of the solenoid. When the sole-noid operates, the magnetic forces flex the side plates toward each other. Repeated operations can cause fracture of the side plates. See 2.4.1.3.1 and 2.4.1.3.2 for fracture prevention techniques.

9/10/2020 2:39 PM

Rev . 7


2.4.1.3.1 Stress Relief Heat Treatment

The side plates are heat treated to remove the residual stress from stamping of the plate and extend the fatigue life. Side plates which have received heat treatment for stress relief are marked with a white dot.

2.4.1.3.2 Solenoid Spacers

Solenoid spacers are installed between the side plates to resist the magnetic forces flexing of the plates. When switches are sent to the Vacuum Electric Switch Co. for an overhaul, installation of solenoid spacers are part of the overhaul process to prevent side plate fracture.

Spacers

9/10/2020 2:39 PM Rev. . 7


2.4.1.3.3 Solenoid Vibrating Loose

Solenoids may vibrate loose at their mounting bolts. After a sufficient time, the solenoid will be so loose that it will not have sufficient stroke to operate the switch. Solenoids are prevented from vibrating lose by installing screw-lock helicals in the solenoid’s mounting bolt holes in the switch casting. Installing these helicals is part of Vacuum Electric Switch’s standard overhaul pro-cess.

2.4.2 Control Yoke Failures When a control yoke fractures, the switch immediately stops operating. These fractures are generally the result of cyclic fatigue failure from many switch operations. They most frequently occur in switches used to operate arc furnaces.

2.4.2.1 Yoke Bumper Stop Induced Failure The Joslyn yoke bumper stop has a metal stop which impacts the control. Repeated impact causes an indentation in the control yoke casting. This indention can become a stress point which results in a fracture of the casting. This failure is prevented with a yoke bumper stop that impacts the control yoke with a broad flat rubber surface. The control yoke is not damaged, and fracture does not occur.

9/10/2020 2:39 PM

Rev . 7


2.4.2.1.1 Handle Induced Fracture

The speed of switch operation is so fast that the inertial forces from the mass of the external manual operating handle twist the control yoke. Over many operations the cyclic fatigue from twisting of the control yoke can cause fracture. A handle with reduced mass is installed to extend the fatigue life of the control yoke. The original handles were cast aluminum with no holes. The reduced mass handles can be recognized from the holes in the handle..

Reduced Mass Handle Old Design Handle

2.4.2.1.2 Spring Pin Failure

Fracture of the spring pins which are used to fasten the manual operating handle to its shaft and the shaft to the control yoke, is a common problem. The cause of these failures is cyclic fatigue from the inertial forces of the handle on the spring pins. This failure is prevented by increasing the size of the spring pin from 1/4 to 3/8 inch diameter. The handle shaft diameter needs to be increased as well, which requires re-machining the switch cast-ing for a larger bearing. Such a modification can only be done in Vacuum Electric Switch’s shop. This change also requires a new control yoke with a 2 inch diameter boss on its handle side. The use of stainless steel spring pins will result in stress corrosion fracture of the spring pins. Special Monel spring pins are used to prevent such failures.

Monel Spring Pin

9/10/2020 2:39 PM Rev. . 7


2.4.3 Spring Assembly Failure Spring assembly failures are due to wear in the spring’s draw bars. Over time the draw bar can wear through and the spring becomes detached. Such a failure is prevented by installing lubricating washers and saturating them with motor oil. The use of lubrication can extend the draw bar life to more than 500,000 operations.

2.4.3.1 Toggle Link Bushing Loss The bronze bushings in the control yoke may slide out of place and the link become only loosely attached to the operating mechanism. This failure is prevented by permanently capturing the bearing in the control. Toggle links not having permanently captured bearings are replaced as part of the Vacuum Electric Switch normal over-haul process.

Redesigned casting to perma-nently capture the bushings, preventing displacement.

9/10/2020 2:39 PM

Rev . 7


2.4.3.2 Pull Rod

When a switch is overhauled in the Vacuum Electric Switch shop, pull rods manufactured by Joslyn™ are gener-ally replaced. This is because Joslyn recommended replacing the pull rods each time a module is replaced. Vac-uum Electric Switch is continuing this practice by replacing Joslyn pull rods. Vacuum Electric Switch pull rods do not have to be periodically replaced because they have improved wear and fatigue life.

2.4.3.3 Clevis Fracture

The pull rod clevis can fracture due to cyclic fatigue at the corners of the clevis. This is prevented by providing mechanical support at the corners.

2.4.3.4 Screw Thread Failure

Pull rods have threaded plugs in their ends which screw onto the pull rod screw in the vacuum interrupter mod-ule. The material used for this plug in the past has been aluminum, but aluminum does not wear very well. The plug material has been changed to stainless steel to improve thread life. See photograph at paragraph 2.6.4.

9/10/2020 2:39 PM Rev. . 7


2.5.1.1 Motor Assembly The motor assembly is the one part of the motor mechanism which can easily be replaced. The motor mecha-nism commonly fails due to either a worn worm wheel or worn work shaft bearing journals. These failures are now prevented by changes in material and the addition of lubrication. The result is that replacement Vacuum Electric Switch motor assemblies will be less common than before.

2.5.1.1.1 Worm Wheel

Joslyn motor assemblies had a fiber worm wheel which could have its teeth worn off. This worm wheel has been replaced with a metal wheel with an adjacent felt lubricating washer to provide lubricant on the wheel.

2.5.1.1.2 Shaft Support Bearing

The worm wheel is supported by a shaft with bearing journals in two side plates. Previously, the shaft was made of steel and the side plates brass. Vacuum Electric Switch motor assemblies have a bronze shaft and steel side plates with lubricating washers. The bronze on steel with lubrication is a much better wear combination so that the motor assembly does not wear out as before.

Motor Assembly

Worm Wheel

Lubricating Washer

Shaft Support Bearing

2.5 Motor Operated Switches A motor operated switch gets its energy of operation from a universal motor similar to the motor found in a sew-ing machine. The motor itself is operable on 48VDC or 120VAC. A special motor is available that can operate on 24VDC. The switch can operate on a wide variety of voltages that are accommodated with special relay pan-els. A common mistake is to connect the switch to the wrong voltage, which will drastically shorten the motor’s life. When the motor operates, it stores energy in a spring which is then used to operate the switch. The electric cur-rent to operate the motor is only about five amperes, which enables it to be used in remote locations where only small amounts of electrical power is available. The small current also means that no special controls are re-quired to operate the switch.

2.5.1 Motor Mechanism Motor mechanisms are somewhat like a grandfather clock mechanism. If you take one apart, you will soon wish you hadn’t. With the exception of replacing the motor assembly, the motor mechanism is not a part which should be repaired by an inexperienced person. The motor mechanism has seven parts: two boomerangs, two side plates, two spring bolts, and one toggle link, which commonly fail. The amount of work involved in taking a motor mechanism apart is so great that if any one of these parts needs to be replaced, all of them should be replaced at the same time. Also, the cost in time and parts is so great that purchasing a new mechanism is faster and probably less expensive than doing a repair.

9/10/2020 2:39 PM

Rev . 7


2.5.1.2 Ratcheting Cams

The motor mechanism contains four ratcheting cams. If these cams do not grip their shafts properly, the springs cannot be recharged in preparation for the next switch closing and opening operation. It is possible for one set of cams to be working properly and the other set to fail. In this situation, the time re-quired to recharge the springs for the next operation is doubled. Cams fail to operate properly because they must be installed in a precisely sized hole in the boomerang. If the hole is not the correct size the cam will slip. Formerly, boomerangs were made of aluminum, but Vacuum Elec-tric Switch boomerangs are now made of stainless steel. The stainless steel is much stronger, and the hole size better controlled to prevent cam slippage.

2.5.1.3 Trip Link Trip Free Failure

The trip link is adjusted by a steel screw which impacts the link. Before, trip links were made of aluminum, but now Vacuum Electric Switch trip links are made of steel. The steel has better wear characteristics so that the link does not get out of adjustment.

Boomerang

Adjustment Screw

Trip Link

9/10/2020 2:39 PM Rev. . 7


2.5.1.4 Spring Tab

The motor operator is powered by springs which are attached to the side plates of the motor operator mechanism. In the past, the attachments were fillet welded to the side plate. These tabs sometimes broke off and the spring would go flying. The mounting tabs on Vacuum Electric Switch side plates are keyed into the side plates and then brazed so that they cannot break off.

Old Design New Design

2.5.1.5 Bolt Failure

The springs storing energy for the operation to the motor mechanism were attached by relatively small bolts which were subject to bending in the threads. The bolt could fracture, and the spring go flying. This part in the Vacuum Electric Switch motor mechanism is changed to a more substantial eye-bolt that can withstand the bending stresses of the application.

The spring shown to the left is used to store energy for the motor operator mechanism. Bolts are used to fas-ten the energy storage springs to the motor mechanism.

Cyclic fatigue can cause the bolt holding the spring to fail between the shaft and the jam nut. This failure can result in the bolt and the spring becoming dangerous pro-jectiles.

This failure is prevented by redesigning the parts holding spring as a rod end, as shown to the left. The rod end has a larger diameter than the bolt formerly used and increases it’s ability to resist the bending force created by the spring. Fatigue failures are then prevented.

FOR SPRING

Spring Bolt

9/10/2020 2:39 PM

Rev . 7


2.6.1 Link Angle The link angle is adjusted by moving the opening bumper. The Joslyn™ switch literature says that the link angle should be set at 1 degree, tilted in the direction opening. As the bumper wears the link angle becomes smaller. If the bumper wears so much that the link angle goes over top dead center, the opening speed of the switch open-ing is slowed. For solenoid operated switches, slow operations will be detected by the control and attempt to open the switch with the under-voltage-trip capacitors. A fuse will be blown. On an arc furnace this may cause an arrestor to explode. For solenoid operated switches used on arc furnaces the link angle should be set at 3 degrees to give a larger wear allowance. For switches having double stack modules the link angle should be set at 1 degree. Because the customary num-ber of operations is not so large as to require the extended life required for an arc furnace switch. The link angle for motor operated switches must be set at 1 degree. If it is set larger, the motor operator mecha-nism will trip free. Bumper wear is very important in maintaining the link angle. Previously, bumpers were made with plastisol, but this material did not wear well. Vacuum Electric Switch bumpers are now made with urethane material which is very tough and durable and suffers minimal wear. Using urethane bumpers allow a switch to stay adjusted for long term operations.

Link Angle

2.6 Loss of VBM and VBT Adjustments

9/10/2020 2:39 PM Rev. . 7


2.6.2 Full Travel The full travel adjustment sets the open gap of the vacuum interrupter. This adjustment should be set between 0.200 and 0.210 inches and is set by the opening bumper. Minimizing bumper wear is very important in main-taining the full travel adjustment over a large number of operations. Bumper assemblies with urethane (rather than plastisol) bumpers should be used to maintain the full travel adjustment over a large number of operations.

Full Travel Adjustment

2.6.3 Bearing Wear The vacuum switch mechanism consisting of links, actuating bars, and the support bar is assembled using many ¼ inch diameter ground shafts. Where the shafts go through these parts, only some of the parts had oil impreg-nated sintered bronze bush bearings. In some locations the bearing journal was just a drilled hole through an aluminum bar. Aluminum does not wear well, and these holes would be out of round. Worn bearings and out-of-round bearing journals make switches difficult to adjust. Bearing wear can be as-sessed by amount of play in the mechanism observed between rocking the mechanism in one direction and then reversing it to go the other. If the travel adjustment measurement changes on reversing directions, the bearing has too much wear. New switches manufactured by the Vacuum Electric Switch Co. have oil impregnated bearings for all ¼ inch shaft bearing journals. On repaired switches, the old drilled journals in the aluminum bar are drilled out and new oil impregnated bronze bushings installed. All other ¼ inch bronze bushings are replaced during a switch over-haul.

2.6.4 Pull Rod Thread Wear The vacuum interrupter is attached to its pull rod with a 5/16-18 threaded screw which is screwed into a threaded plug in the end of the pull rod. Formerly, parts were made of aluminum which did not wear well. Now both the screw and the plug are made of stainless steel which wears much better. The wear in these threads causes hyste-resis in the module synchronism adjustment and makes a switch difficult to adjust. Changing the material of both the pull rod screw and the pull rod plug eliminates this problem. During switch overhauls aluminum pull rod screws in Joslyn modules are removed and replaced with stainless steel screws.

9/10/2020 2:39 PM

Rev . 7


2.6.5 Clevis Slippage The pull rod clevis is used to adjust the overtravel of the vacuum interrupter contacts. If the clevis adjustment slips, the switch is out of adjustment. Slippage is prevented by machining teeth into the gripping surface of the clevis. The clevis is tightened using grade 8 high strength fasteners, flat washers, and lock washers. The flat washers distribute the bolt tension broadly over the clevis teeth. In times past, stainless steel bolts and spring lock washers have been used for this application. Stainless steel lock washers are not appropriate because they are subject to stress corrosion fracturing, which makes them go flat. Using flat lock washers does not maintain the bolt tension and slippage becomes possible.

9/10/2020 2:39 PM Rev. . 7


2.6.8 Module Cross Pin Wear Method One: The pull rod screw is pinned to the copper conductor with a steel pin. During operation of the switch, force is applied to the pin and over repeated operations, the hole in the soft copper slowly enlarges. Movement of the pin in the hole causes hysteresis in the contact synchronism adjustment.

Method Two: Loss of adjustment does not occur in this method, which separates the electrical and mechanical functions. Electricity is conducted by a copper sleeve which surrounds a steel sleeve. The steel sleeve makes the mechanical connection between the pull rod and the vacuum interrupter moving stem. The pull rod screw is pinned to a hole in the steel sleeve, preventing wear of the hole. A lubricant is packed inside the steel sleeve to reduce wear as the pull rod screw slides against the pin.

2.6.6 Overtravel Spring Lubrication The overtravel spring in the vacuum interrupter is packed with molybdenum disulfide wheel bearing grease. The spring is associated with various parts including the cross pin and the pull rod screw. These parts rub on each other during the operation of the switch. If they are not lubricated, wear will prevent them from sliding smoothly on each other. The result will be a stick-slip motion that makes module synchronism adjustments dif-ficult.

2.6.7 Pull Rods Clevis slippage will result in a switch getting out of adjustment. Refer to paragraph 2.6.5 for discussion.

Method One Method Two

9/10/2020 2:39 PM

Rev . 7


2.6.9 Auxiliary Switch Solenoid operated switches have been manufactured with many different types of auxiliary switches. Loss of adjustment of the auxiliary switch can cause improper switch operation. The two switches commonly encoun-tered are the Eaton™ and the Square D™ switch.

2.6.9.1 Eaton™ Aux Switch The Eaton switch shown below is made to military specifications and our testing has shown that is has a me-chanical life of approximately 500,000 operations. Although we have not tested other auxiliary switches exten-sively, antidotal evidence suggests the Eaton switch is the most reliable, established through product history and wide-ranging assessment. If downtime is unacceptable and auxiliary switch failures are to be avoided, the Eaton switch should be replaced at 250,000 operations.

2.6.9.2 Square D™ Auxiliary Switch Switches sent in for an overhaul that have Square D auxiliary switches have these switches removed and re-placed with the Eaton auxiliary switches. The reason for this is that the plastic housing for the Square D switch frequently becomes cracked and fails. Replacing the Square D switch with the Eaton switch prevents this prob-lem. Field replacement of a Square D switch may not always be possible because the necessary mounting holes for the Eaton switch may not be available.

Square D™ Switch

9/10/2020 2:39 PM Rev. . 7


VBU switches are shown on page 10 of this catalog. The major operating components are the vacuum interrupt-er module and the operating mechanism which are shown on page 40. Both the module and the mechanism have undergone significant design changes that improved reliability and longevity of this switch. Improvements in the module are explained below.

3.1 Modules The Vacuum Electric Switch Company is manufacturing a new replacement VBU module which incorporates design improvements to keep moisture out of the module and to prevent increases in terminal-to-terminal re-sistance.

3.1.1 Moisture Ingress Leakage of moisture into a VBU module stack sometimes resulted in internal flashovers. Three design changes have been implemented to eliminate this problem. First, the cross sectional diameter of the O-ring seal between the modules has been increased from 1/8 to 1/4 inch. The larger cross section allows more compression of the O-ring so that the seal is more tolerant of any joint relaxation that may occur during the module’s life. The second design change was to fasten the modules together using materials that are stronger and harder than the aluminum bolts previously used. Third, the threads in the aluminum casting are strengthened with stainless steel threaded inserts.

Stainless Steel Bolt

Large O-ring

Stainless Steel Belleville Washer

Thick Stainless Steel Flat Washer

3. VBU Switches

Threaded Insert

9/10/2020 2:39 PM

Rev . 7


High strength bolts, Belleville washers, and flat washers - used to prevent module electrical resistance from increasing

3.1.2 Increase in Resistance Keeping the electrical resistance low requires the compressive forces on all the electrical mechanical joints to be maintained. The design improvements which prevent moisture leakage also maintain the forces on the joints and tend to prevent increases in module-to-module resistance. VES remanufactured modules have always used high strength fasteners. Belleville and flat washers and screw-lock helical inserts in the mechanical joints inside the module prevent increases in electrical resistance. Over the long haul, these measures have prevented the internal resistance from increasing in VES remanufactured mod-ules. These measures are continuing to be used in new VES modules.

9/10/2020 2:39 PM Rev. . 7


3.1.3 Loss of Adjustments When VBU modules are stacked together to make a VBU pole, the modules must be synchronized before the switch is put into operation. Synchronizing is the adjustment of the modules so that their contacts all open and close at the same time. This synchronization must be maintained throughout the life of the switch. If it is lost, the switch might fail catastrophically. During the operation of the switch, the vacuum interrupter contacts are subject to impact loads on closing and continuous loads of seventy pounds during switch operation. Repeated impacts of closing can slowly move the vacuum interrupter’s location. The result would be that the contact buttons of the vacuum interrupters in series would no longer all open and close at the same time. Loss of synchronization is prevented by having the vacuum interrupter solidly mounted and attached to the module housing. The vacuum interrupter is attached to a strong aluminum support bracket which is then bolted to the module housing using high strength bolts, Belleville, and flat washers. The tapped bolt holes in the alu-minum flange casting are reinforced with screw-lock helical inserts.

Potted Vacuum Interrupter

Strong Mounting Bracket

Date post:	16-Nov-2023
Category:	Documents
Upload:	khangminh22
View:	0 times
Download:	0 times

Vacuum Electric Switch Co. - VESCO

Documents